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Previous Screen Product: EXCAVATOR Model: 315 L EXCAVATOR 6YM Configuration: 315 315L TRACK-TYPE EXCAVATOR

Product: EXCAVATOR Model: 315 L EXCAVATOR 6YM Configuration: 315 315L TRACK-TYPE EXCAVATOR 6YM00001-UP (MACHINE) POWERED BY EXCAVATOR Model: 315 L EXCAVATOR 6YM Configuration: 315 315L TRACK-TYPE EXCAVATOR 6YM00001-UP (MACHINE) POWERED BY 3046 ENGINE

Testing and Adjusting

315 AND 315 L EXCAVATORS HYDRAULIC SYSTEMS

Media Number -SENR6187-00

Testing And Adjusting

Introduction

Publication Date -26/10/1994

NOTE: This manual is divided into the following two main sections:

1. Checking Procedures

2. Testing And Adjusting

Shutdown SIS
Shutdown SIS

Date Updated -12/10/2001

Hydraulic Systems Testing And Adjusting sections are provided for the person who is more familiar with the combined operation of the electronics and hydraulics.

NOTE: As a general rule, if there is a doubt to the cause of a problem, the electronic system should be checked first.

Reference: For information on Systems Operation of the above, see the following: Systems Operation, Electric And Electronic Systems, SENR6185 and/or Systems Operation, Hydraulic System, SENR6186.

This manual contains information on the troubleshooting procedures of the hydraulic systems in the 315 excavators. For troubleshooting the engine components, refer to the module Systems Operation, Testing And Adjusting, Basic Engine Components 3054 Engine, SENR or Systems Operation, Testing And Adjusting, Basic Engine Components 3046 Engine, SENR6457

Checking Procedures

In each checking procedure, it is assumed that the engine operation is normal unless otherwise specified.

Electronic Control System

The monitor and electronic controller are the main components of the electronic control system. The monitor and electronic controller have a self diagnostic function. Self diagnostic checks of the monitor, electronic controller, and the communication line between them are the first steps when troubleshooting the problem(s) in the electronic system.

Action alarm indicators on the monitor panel, alert an operator to a problem in the electronic system. The controller service program "Data Mode" can also be used to identify the problems (see the section of this module "Data Mode"). If the service program is activated during machine operation, problem(s) that are monitored by the monitoring system are indicated on the character display. If the service program is activated when the machine operation is stopped, all existing problems and past problems (problems that have not been corrected) are indicated on the character display. To activate the controller service program "Data Mode", refer to the "Data Mode" section in this module.

Reference: For information on operation of the "Data Mode", make reference to: "Systems Operation, Testing And Adjusting, Engine And Pump Electronic Control System", Form SENR6155.

Operational Tests

If the electronic power unit control system display indicates it is operating correctly, then do operational tests. Operate the machine, following the procedures described in the section "Hydraulic System Testing And Adjusting". Compare the results of the operational tests with specifications to determine the extent of the trouble. In operational tests, it is important to determine whether

or not enough hydraulic force or implement speed is a problem that extends over the entire machine or with only a specific operation.

If there are any faults in the circuits between the main or pilot pumps and the control valves, the overall performance of the machine will decrease. This type of problem in the hydraulic system is not detected by the self diagnostic functions of the electronic control system described above (no action alarm indication on character display.). To detect such a problem, it is necessary to check the flow characteristics of the pumps, the main relief pressure, pilot pressure, etc.

Checking Procedures

Hydraulic System Checking Procedures

(Hyd #1) Hydraulic Oil Supply

Reference: Refer to "Operation and Maintenance Manual", for the specific machine.

(Hyd #2) Suction Filter Cleaning

Reference: Refer to "Operation and Maintenance Manual", for the specific machine.

(Hyd #3) Adjustment Of Pressure And Flow

Reference: Refer to the section in this module, "Hydraulic System Testing And Adjusting, Pressure Adjustment".

Reference: Refer to the section in this module, "Hydraulic System Testing And Adjusting, Prmp Flow Tests".

(Hyd #4) Check Of Pilot Pressure To Main Control Valves

(Hyd #4) Check Of Pilot Pressure To Main Control Valves Main Control Valve Compartment (Viewed From

Main Control Valve Compartment (Viewed From Machine Rear) (1) Pilot line (stick I in). (2) Pilot line (swing right). (3) Pilot line (forward left travel). (4) Pilot line (forward right travel). (5) Pilot line (boom I raise). (6) Pilot line (bucket close).

1. To check the pilot pressure at each inlet port of the main control valves, connect a tee between each pilot line and its control

valve.

2. Attach a 4750 kPa (700 psi) pressure gauge to the tee.

3. With the hydraulic activation control lever in the UNLOCKED position, operate the pilot control lever for each function.

(Hyd #5) Swing Motor Performance Problem (Measurement Of Case Drain Oil)

the pilot control lever for each function. (Hyd #5) Swing Motor Performance Problem (Measurement Of Case
Swing Motor Compartment (1) Drain line. (2) Tee. (3) Drain line. In Front Of Main

Swing Motor Compartment (1) Drain line. (2) Tee. (3) Drain line.

Motor Compartment (1) Drain line. (2) Tee. (3) Drain line. In Front Of Main Control Valves

In Front Of Main Control Valves (4) Elbow. (5) Pilot line.

To check the swing motor performance, measure the amount of swing motor case drain oil as follows:

1. Stop the engine. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In The

Hydraulic System".

2. Disconnect case drain line (1) from tee (2) on the swing motor.

3. Install a plug (3/4-16UN) in the end of case drain line (1) and a cap (3/4-16UN) in the open end of tee (2).

4. Disconnect case drain line (3) from the swivel. Put the open end of case drain line (3) into a suitable measuring container.

5. Install a cap (3/4-16UN) in the open port of the swivel.

6. Engage the swing parking brake as follows:

a. Disconnect pilot line (5) from elbow (4).

b. Install a cap (7/16-20UN) on line (5). Leave the end of elbow (4) open to the air.

7. Start and run the engine at high idle speed of 2180 ± 80 rpm. Place the power mode switch in MODE III position.

8. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).

9. Operate the swing control for one minute. Measure the amount of swing motor case drain oil and record the measurement.

NOTE: Check to be sure that the swing parking brake is correctly engaged while the swing control is being activated.

10. Disengage the swing parking brake as follows:

a. Stop the engine and release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In The Hydraulic System".

b. Remove cap (7/16-20UN) from elbow (4).

c. Connect pilot line (5) to elbow (4).

11. Operate the swing control to place the swing motor barrel at a new position.

12. Repeat steps 1 through 9. Take three measurements.

NOTE: The maximum acceptable case oil with a swing relief pressure setting of 23 000 ± 980 kPa (3350 ± 140 psi) must be:

For a New swing motor

For a Rebuilt swing motor

15 liter/min (4.0 U.S. gpm)

17 liter/min (4.5 U.S. gpm)

(Hyd #6) Travel Motor Performance Problem (Measurement Of Case Drain)

Travel Motor Performance Problem (Measurement Of Case Drain) Travel Motor (1) Connector. (2) Drain line. To
Travel Motor Performance Problem (Measurement Of Case Drain) Travel Motor (1) Connector. (2) Drain line. To

Travel Motor (1) Connector. (2) Drain line.

To check the travel motor performance, measure the amount of case drain oil as follows:

1. Stop the engine. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In The

Hydraulic System".

2. Disconnect drain line (2) from connector (1). Install a plug (9/16-18UN) in the open end of drain line (2).

3. Connect one end of the vinyl hose to connector (1) and put the other end of the vinyl hose into a suitable measuring container.

4. Start and run the engine at high idle speed of 1980 ± 80 rpm. Place the power mode selector switch in MODE III position.

5. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).

6. With the track blocked, operate the travel control for one minute.

7. Measure the amount of case drain oil.

8. Remove the track block, and move the machine forward to place the travel motor barrel in a new position.

9. Repeat steps 1 through 7. Take three measurements.

NOTE: The maximum acceptable case drain oil with a main relief pressure of 34 300 ± 1470 kPa (5000 ± 215 psi) must be:

For a New travel motor

For a Rebuilt travel motor

20 liter/min (5.3 U.S. gpm)

23 liter/min (6.1 U.S. gpm)

Testing And Adjusting

Introduction

Testing And Adjusting Introduction Hydraulic oil pressure can remain in the hydraulic systems on this machine

Hydraulic oil pressure can remain in the hydraulic systems on this machine 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 section, Release Of Pressure In The Hydraulic System, before any fitting, hose or component is loosened, tightened, removed or adjusted.

When possible, the bucket 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 boom, stick and bucket have correct support.

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.

engine is running and tests or adjustments are being made. During diagnosis of the hydraulic system,

During diagnosis of the hydraulic system, remember that correct oil temperature, flow, and pressure are necessary for correct operation. Pump output (oil flow) is a function of engine speed (rpm). Oil pressure is caused by resistance to the flow of oil.

Visual Checks

A visual inspection of the system is the first step when troubleshooting a problem. Make the inspection with the engine off and the

implements lowered to the ground.

1. Check the level of the oil in the hydraulic tank. Slowly loosen the hydraulic tank pressure cap and release the pressure before

the fill/vent plug is removed.

2. Remove the filter element and check it 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 linkage for bent, broken, or damaged components.

Checks During Operation

The checks during operation can be used to find leakage in the system. They can also be used to find a valve, pump, motor, or cylinder that is not working correctly. The speed of rod movement or the torque on a motor can be used to check the condition of the cylinders, motors, and pumps.

Operational Tests

NOTE: For specifications given in "Operational Tests", a "NEW" specification is the performance that can be expected for a new machine. A "REBUILD" specification is the performance target to use after rebuilding the components of a system. A machine that performs beyond "Service Limit" specifications should be checked for improper maintenance or adjustment, component wear,

or failure.

Specifications given in charts for a machine equipped with 5100 mm (16 ft 9 in) boom, 2600 mm (8 ft 6 in) stick, and SAE 0.65

m 3 (7/8 yd 3 ) bucket.

NOTE: The power mode selector switch must be placed at MODE III position and the work mode selector switch be in BOOM

PRIORITY MODE position, unless otherwise specified, during tests.

Operational Test Preparations

specified, during tests. Operational Test Preparations 1. Engine speed: Excavator with no load at high idle,

1. Engine speed:

Excavator with no load at high idle, 2180 ± 80 rpm

speed: Excavator with no load at high idle, 2180 ± 80 rpm 2. Hydraulic oil temperature:

2. Hydraulic oil temperature: 55 ± 5°C (131 ± 9°F)

NOTE: Fully move the stick in and out several times until the normal hydraulic oil temperature is reached.

3. Relief valve pressure settings are set according to specification.

Reference: Make reference to the section in this module "Relief Valves", "Specifications".

Straight Travel Test

Valves", "Specifications". Straight Travel Test Determining if there is a deviation to the right or left

Determining if there is a deviation to the right or left during straight travel can identify a problem with the travel motors or main pumps.

Test Preparation:

1. Set engine speed and increase the hydraulic oil temperature to the normal operating temperature.

1. Set engine speed and increase the hydraulic oil temperature to the normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft) long.

3. Draw a 25 m (82.5 ft) straight line on travel test ground as a reference line.

4. Position the machine so that one track is in line (parallel) with the reference line. Put the machine in the travel test position as

shown in the illustration.

5. The bucket must be empty.

Test Procedure:

1. Start the engine and place the power mode selector switch in MODE III position. Place the engine speed dial at position "10"

and the travel speed switch in HIGH (rabbit) position. Move the machine by operating both travel levers at the same time.

2. The first 5 m (16.5 ft) are for a preliminary run.

3. Measure the travel deviation from the reference line.

NOTE: Refer to the chart in the section, "Travel Test On Level Ground" for travel deviation from the reference line specifications.

NOTE: If the travel deviation from the reference line is beyond the specification then the travel motors and main pumps may need adjustment.

Component Test:

To determine if the travel motors need adjustment do the following procedure:

1. Start the engine and place the power mode selector switch in MODE III position. Place the engine speed dial at position "10"

and the travel speed switch in HIGH (rabbit) position. Move the machine by operating both travel levers at the same time.

2. The first 5 m (16.5 ft) are for a preliminary run.

3. While in straight travel extend the bucket cylinder.

If the forward travel no longer drifts to one side the problem is with the travel motors or swivel. If the machine continues to drift while extending the bucket cylinder then check the adjustment of the main pumps.

Travel Test On Level Ground

Test Preparation: 1. Set engine speed and increase the hydraulic oil temperature to the normal

Test Preparation:

Test Preparation: 1. Set engine speed and increase the hydraulic oil temperature to the normal operating

1. Set engine speed and increase the hydraulic oil temperature to the normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft) long.

3. Draw a 25 m (82.5 ft) straight line on travel test ground as a reference line.

4. Position the machine so that one track is in line (parallel) with the reference line. Put the machine in the travel test position as

shown in the illustration.

5. The bucket must be empty.

Test Procedure:

1. Start the engine and place the power mode selector switch in MODE III position. Place the engine speed dial at position "10"

and the travel speed switch in HIGH (rabbit) position. Move the machine by operating both travel levers at the same time.

2. The first 5 m (16.5 ft) are for a preliminary run. Measure the time required for the machine to travel the remaining 20 m (66 ft)

in each direction (forward and reverse).

3. Measure the travel deviation from the reference line.

4. Repeat the above procedure with the travel speed switch in LOW (turtle) position.

NOTE: The following chart represents the time (in seconds) it should take to complete the 20 m (66 ft) test run:

NOTE: The following chart represents the time (in seconds) it should take to complete the 20

NOTE: The following chart represents the travel deviation from the reference line:

represents the travel deviation from the reference line: Travel On Level Ground (Optional Test) NOTE: If

Travel On Level Ground (Optional Test)

NOTE: If suitable ground (as stated in Step No. 2 in "Test Preparation" for "Travel On Level Ground") cannot be found, the following test should be done as a substitute:

be found, the following test should be done as a substitute: Test Preparation: 1. Set engine

Test Preparation:

1. Set engine speed and increase the hydraulic oil temperature to the normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground.

3. Raise a track for the test as shown in the illustration.

4. Put a mark on a shoe of the raised track.

Test Procedure:

Put a mark on a shoe of the raised track. Test Procedure: 1. Start the engine

1. Start the engine and place the power mode selector switch in POWER MODE III position. Run the raised track with the engine

speed dial at position "10" (HIGH IDLE) and the travel speed switch in HIGH (rabbit) position.

2. Measure the time required for the track to make three complete turns (revolutions) in each direction (forward and reverse).

Drift On A Slope Measuring the amount of drift of the machine on a slope
Drift On A Slope Measuring the amount of drift of the machine on a slope

Drift On A Slope

Drift On A Slope Measuring the amount of drift of the machine on a slope will

Measuring the amount of drift of the machine on a slope will determine if there is a need to check the travel brake.

Test Preparation:

there is a need to check the travel brake. Test Preparation: 1. Place the machine on

1. Place the machine on a slope of 12°. The slope surface must be hard and smooth.

2. Put the implements in the position shown in the illustration.

3. Bucket should be empty.

Test Procedure:

1. Put marks on both track and ground to indicate its relative position to the

1. Put marks on both track and ground to indicate its relative position to the slope.

2. Stop the engine and time three minutes (using a stopwatch).

3. Measure (with a scale) the distance the tracks have moved on the slope.

a scale) the distance the tracks have moved on the slope. Swing Speed And Over Swing

Swing Speed And Over Swing (On Level Ground)

on the slope. Swing Speed And Over Swing (On Level Ground) Measuring the swing speed and

Measuring the swing speed and over swing of the machine will determine if there is a need to check the swing motor and/or anti- reaction valve.

Test Preparation:

1. Set engine speed and increase the hydraulic oil temperature to the normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground as shown in the illustration.

to the section "Operation Tests Preparation" 2. Place the machine on level ground as shown in

3.

Put marks on both inner and outer races of the swing bearing to indicate relation of two positions.

of the swing bearing to indicate relation of two positions. 4. The bucket should be empty.

4. The bucket should be empty.

Test Procedure (Over Swing):

1. Start the engine and place the power mode selector switch in POWER MODE III position. Place the engine speed dial at

position "10" (HIGH IDLE).

2. Move the swing control lever to the RIGHT or LEFT positions until the machine completes a 180° swing operation. Return the

swing control lever to the NEUTRAL position at the end of the 180° swing operation and measure the amount of over swing by measuring the distance between the marks on the swing bearing.

NOTE: Use a reference point that is visible from the operator's seat as a indicator of when to stop the 180° rotation.

seat as a indicator of when to stop the 180° rotation. Test Procedure (Speed): Move the

Test Procedure (Speed):

Move the swing control lever to the LEFT or RIGHT positions and measure the time it takes to complete a 180° swing operation.

or RIGHT positions and measure the time it takes to complete a 180° swing operation. Swing

Swing Speed And Drift (On A Slope)

or RIGHT positions and measure the time it takes to complete a 180° swing operation. Swing

Measuring the swing speed on a slope will determine if there is a need to check the swing motor and/or anti-reaction valve. Measuring the swing drift on a slope will determine if there is a need to check the swing parking brake.

Test Preparation:

1. Place the machine on a 12° slope.

Test Preparation: 1. Place the machine on a 12° slope. 2. Place the implements at maximum

2. Place the implements at maximum reach and fill the bucket with soil. The bucket should be positioned above the ground to clear

any obstructions.

Test Procedure (Speed):

1. Stop the machine on a slope of 12°. Place the upper structure at a 90° angle to the lower structure as shown in the illustration.

angle to the lower structure as shown in the illustration. 2. Measure the time needed to

2. Measure the time needed to swing the upper structure 90° counterclockwise. Do the same for a 90° swing clockwise.

counterclockwise. Do the same for a 90° swing clockwise. Test Procedure (Drift): 1. Stop the machine

Test Procedure (Drift):

1. Stop the machine on a slope of 12°.

3. Put marks on the inner and outer races of the swing bearing. 4. Stop

3. Put marks on the inner and outer races of the swing bearing.

Put marks on the inner and outer races of the swing bearing. 4. Stop the engine.

4. Stop the engine.

5. Leave the machine in this position for three minutes, and measure swing drift on the circumference of the swing bearing.

6. Rotate the upper structure 180° from the original position as described in Step 1.

7. Repeat Steps 2 through 5.

180° from the original position as described in Step 1. 7. Repeat Steps 2 through 5.

Cylinder Drift

180° from the original position as described in Step 1. 7. Repeat Steps 2 through 5.

Test Preparation:

1. Set engine speed and increase the hydraulic oil temperature to the normal operating temperature.

1. Set engine speed and increase the hydraulic oil temperature to the normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground as shown in the illustration.

3. Fill the bucket with soil.

Test Procedure (For Boom And Stick Cylinders):

1. Fully extend the bucket cylinder.

2. Fully retract the stick cylinder.

3. Raise the boom until its upper surface becomes parallel to the ground.

4. Measure each cylinder's length from pin to pin.

5. Stop the engine.

6. Leave the machine in this position for three minutes, then measure each cylinder's length from pin to pin for drift.

Test Procedure (For Bucket Cylinder):

pin to pin for drift. Test Procedure (For Bucket Cylinder): 1. Fully extend the bucket cylinder.

1. Fully extend the bucket cylinder.

3.

Measure each cylinder's length from pin to pin.

4. Stop the engine.

5. Leave the machine in this position for three minutes, then measure each cylinder's length from pin to pin for drift.

each cylinder's length from pin to pin for drift. Cylinder Operating Speed Test Preparation: 1. Place

Cylinder Operating Speed

length from pin to pin for drift. Cylinder Operating Speed Test Preparation: 1. Place the machine

Test Preparation:

1. Place the machine on level ground.

2. Bucket must be empty.

Test Procedure (Boom Cylinders):

1. Fully retract bucket and stick cylinders.

Extension test;

Measure the time required for the boom cylinders to reach full extension position starting with the bucket on the ground.

extension position starting with the bucket on the ground. Retraction test; Measure the time required for

Retraction test;

Measure the time required for the bucket to come in contact with the ground from the full extension position of the boom

cylinders.

Test Procedure (Stick Cylinder):

1. Position the upper surface of the boom parallel to the ground and fully extend the bucket cylinder.

Extension test;

Measure the time required for the stick cylinder to reach full extension position from full retraction position.

reach full extension position from full retraction position. Retraction test; Measure the time required for the

Retraction test;

Measure the time required for the stick cylinder to reach full retraction position from full extension position.

Test Procedure (Bucket Cylinder):

1. Position the upper surface of the boom parallel and the stick perpendicular to the ground.

Extension test;

Measure the time required for the bucket cylinder to reach full extension position from full retraction position.

reach full extension position from full retraction position. Retraction test; Measure the time required for the

Retraction test;

Measure the time required for the bucket cylinder to reach full retraction position from full extension position.

Release Of Pressure In The Hydraulic System Release the pressure in the implement hydraulic circuits

Release Of Pressure In The Hydraulic System

Release the pressure in the implement hydraulic circuits (boom, stick, and bucket) before any hydraulic lines or components are disconnected or removed.

1. Fully retract the stick cylinder rod.

2. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.

3. Lower the boom until the bucket is flat on the ground.

4. Shut off the engine and put the hydraulic activation control lever in the UNLOCK position.

5. Move the control levers for boom, stick, and swing to all FULL STROKE positions. This will release any pressure that might be

present in the pilot system.

6. Slowly loosen the air vent plug on the hydraulic tank and release the pressure.

7. Tighten the air vent plug on the hydraulic tank.

8. The pressure in the hydraulic system has been released and lines and components can be removed.

Release Of Air From Main Pumps

When the main pumps have been serviced or the hydraulic oil replaced, remove air from the hydraulic system as follows:

NOTICE

No attempt should be made to start the engine until the main pumps have been filled with hydraulic oil, or serious damage can be caused to hydraulic components.

main pumps have been filled with hydraulic oil, or serious damage can be caused to hydraulic

Pump Compartment

(1) Air vent plug.

1. With the engine stopped, disconnect hose (1) from the top of the main pump. Leave the hose disconnected for several minutes

until the main pumps are filled with oil. Connect hose (1) to the top of the main pumps and start the engine in low idle and fully

raise the boom and hold it in this position.

2. Stop the engine and slowly lower the boom until the bucket is on the ground. This pressurizes the hydraulic tank.

3. Slowly loosen hose (1) until oil flows out of the hose opening. This is an indication that the air has been released from the

pump.

4. Tighten the air vent plug to the specified torque.

Pressure Adjustment

Specifications

NOTE: A new or rebuilt machine must perform according to New or Rebuild specifications. A machine that performs beyond Service Limit Specifications must be checked for improper adjustment, wear, or damage of relief valves or pumps.

adjustment, wear, or damage of relief valves or pumps. Hydraulic Component Layout (1) Right travel motor.

Hydraulic Component Layout (1) Right travel motor. (2) Pilot oil manifold. (3) Main control valves. (4) Swing motor. (5) Boom. (6) Cab. (7) Left travel motor.

Adjustment Procedures NOTE: Values given above are approximate. Use a pressure gauge for adjustment. Relief

Adjustment Procedures

Adjustment Procedures NOTE: Values given above are approximate. Use a pressure gauge for adjustment. Relief Valve
Adjustment Procedures NOTE: Values given above are approximate. Use a pressure gauge for adjustment. Relief Valve

NOTE: Values given above are approximate. Use a pressure gauge for adjustment.

Relief Valve Adjustment Preparation

Pump Compartment (1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).

Pump Compartment (1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).

1. Place the machine on level ground and stop the engine.

2. Release the pressure in the hydraulic system according to the section, "Release Of Pressure In The Hydraulic System".

3. Connect 49 00 kPa (7100 psi) pressure gauge to either the main pump tap (2) or tap (3).

4. Connect a 4900 kPa (700 psi) pressure gauge to tap (1).

5. Start the engine and move the stick IN and OUT to its FULL TRAVEL position. Do this operation several times until the

hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).

6. Place the power mode selector switch in MODE III position.

7. Place the engine speed dial at position "10". Make sure that engine speed under a no load condition is 2180 ± 80 rpm and the

AEC switch is in the OFF position. (Read rpm after an elapse of 3 seconds once the speed dial has been placed in position "10".)

Pilot Relief Valve Adjustment

Preparation

"10".) Pilot Relief Valve Adjustment Preparation Pump Compartment (1) Tap (power shift pressure). (2) Tap

Pump Compartment (1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).

shift pressure). (2) Tap (front pump). (3) Tap (rear pump). Pilot Oil Manifold Compartment (25) Tap.

Pilot Oil Manifold Compartment (25) Tap. (pilot pump delivery pressure). (26) Screw. (27) Locknut. (28) Pilot relief valve.

1. Place the machine on level ground and stop the engine.

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic System".

4.

Start the engine and move the stick IN and OUT to its FULL TRAVEL position. Do this operation several times until the

hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).

5. Place the power mode selector switch in MODE III position.

6. Place the engine speed dial at position "10". Check that engine speed under no load is at specified rpm with AEC switch in the

OFF position. (Read rpm 3 seconds after the speed dial switch has been placed in position "10".)

NOTE: See the section, "Operational Test Preparations" for the specified engine rpm for dial position "10".

NOTE: Normal operations (see characteristic curve) of the engine and pumps are necessary for the pressure adjustment. If the results of the pressure adjustment are not correct, then the engine and pump characteristic curve needs to be checked.

Adjustment Procedure

1. Loosen locknut (27) of pilot relief valve (28).

2. Turn screw (26) until the pressure gauge at tap (25) reads 3450 +200 -0 kPa (500 +30 -0 psi)

Reference: Turning screw (26) clockwise increases the pressure and turning screw (26) counterclockwise decreases the pressure.

Tighten locknut (27) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).

NOTE: Always make final pressure adjustments on pressure rise.

Temporary Setting Of The Main Relief Valve Pressure

NOTE: The purpose for "Temporary Setting Of The Main Relief Pressure" is done so implement line relief valves and travel relief valves can be adjusted.

line relief valves and travel relief valves can be adjusted. Top Of Main Control Valves (4)

Top Of Main Control Valves (4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.

1. Place the machine on level ground and stop the engine. Release the pressure in the hydraulic system. See the section, "Release

Of Pressure In The Hydraulic System".

2. Slowly move the bucket control lever to the BUCKET OPEN position (full cylinder rod retraction).

3. Check to be sure the main relief valve pressure setting is 31 400 ± 490 kPa (4550 ± 72 psi). See the section "Main Relief Valve

Adjustment".

NOTE: Always make final pressure adjustments on pressure rise.

4. Loosen locknut (5) and turn plunger (4) clockwise until it bottoms out. Tighten locknut (5).

5. Loosen locknut (7) and turn adjuster (6) clockwise a quarter turn. Tighten locknut (7).

Swing Crossover Relief Valve Pressure Check

Swing Motor Compartment (21) Crossover relief valve (right swing). (22) Crossover relief valve (left swing).

Swing Motor Compartment (21) Crossover relief valve (right swing). (22) Crossover relief valve (left swing).

(right swing). (22) Crossover relief valve (left swing). Main Control Valve Compartment (23) Elbow. (24) Pilot

Main Control Valve Compartment (23) Elbow. (24) Pilot line (swing parking brake).

(23) Elbow. (24) Pilot line (swing parking brake). Pump Compartment (1) Tap (power shift pressure). (2)

Pump Compartment (1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).

Preparation

1. Place the machine on level ground and stop the engine.

2. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In The Hydraulic System".

3. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (3).

4. Engage the swing parking brake as follows:

a. Disconnect pilot line (24) from elbow (23).

b. Install a cap (7/16-20HD) on elbow (23). Leave the end of pilot line (24) open to the air.

5. Start and run the engine at high idle (2180 ± 80 rpm). Place the power mode selector switch at MODE III position.

6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).

Check Procedure

1. Slowly move the swing pilot control lever to the FULL RIGHT SWING position and check the pressure of relief valve (21) at

tap (3).

NOTE: Check to be sure that the swing parking brake is correctly engaged while the swing control is being activated.

2.

If the pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new relief valve.

3. To check the relief valve for left swing, slowly move the swing pilot control lever to the FULL LEFT position and check the

pressure of relief valve (22) at tap (3).

4. If the pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new relief valve.

5. After pressure check, disengage the swing parking brake as follows:

a. Stop the engine and release the pressure in the hydraulic system. See the section in this module, "Release The Pressure In The Hydraulic System".

b. Remove the cap (7/16-20UN) from elbow (23).

c. Connect pilot line (24) to elbow (23).

Adjustment Of Line Relief Valve Pressure

Preparation

(23). Adjustment Of Line Relief Valve Pressure Preparation Pump Compartment (1) Tap (power shift pressure). (2)

Pump Compartment (1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).

1. Start the service program "Calibration Mode" and keep the power shift pressure constant at 2250 kPa (325 psi). Read the

pressure gauge attached at tap (1) to monitor the power shift pressure.

NOTE: For further information of "Calibration Mode", see the section in this module "Calibration Mode".

NOTE: During line relief adjustment, do not turn the engine OFF to prevent a change in power shift pressure.

2. Use the pressure gauge at tap (2) to read the line relief pressure for boom and bucket circuits. Use the pressure gauge at tap (3)

to read the line relief pressure for stick circuit. For line relief pressure settings for the implement circuits see the section, "Pressure

Adjustment, Specifications".

NOTE: After adjustment of the line relief valves, return the main relief pressure to its normal setting.

return the main relief pressure to its normal setting. Main Control Valve Compartment (Viewed From Machine

Main Control Valve Compartment (Viewed From Machine Rear) (9) Screw. (10) Locknut. (11) Line relief valve (boom cylinder head end). (12) Line relief valve (bucket cylinder head end). (13) Line relief valve (stick cylinder rod end). (14) Line relief valve (stick cylinder head end).

NOTE: Rod end line relief valves of boom and bucket are located under the main control valves.

NOTE: All of the line relief valves are identical in construction and operation. To adjust the line relief pressure, loosen locknut (10) and turn screw (9). Turning screw (9) clockwise increases the pressure and turning screw (9) counterclockwise decreases the

pressure.

Adjustment (Stick Cylinder)

1. To adjust the pressure in the stick cylinder rod end, move the stick control lever to FULL STICK OUT (rod retracted) position.

Check the pressure in the stick cylinder rod end at tap (3).

2. Return the stick control lever to the NEUTRAL position. Loosen locknut (10) and turn screw (9) until line relief valve pressure

at tap (3) reads 33 300 ± 1470 kPa (4850 ± 215 psi). Turning screw (9) clockwise increases the pressure and turning screw (9)

counterclockwise decreases the pressure.

3. To adjust the pressure in the stick cylinder head end, move the stick control lever to FULL STICK IN (rod extended) position.

Check the pressure at tap (3).

4. Return the stick control lever to the NEUTRAL position. Adjust the line relief valve pressure in the same manner as the stick

rod end.

NOTE: Always make final pressure adjustment on pressure rise.

Adjustment (Bucket Cylinder)

1. To adjust the pressure in the bucket cylinder head end, move the bucket control lever to FULL BUCKET CLOSE (rod

extended) position. Check the pressure in the bucket cylinder head end at tap (2).

2. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve pressure in the same manner as described

for the stick cylinder.

3. To adjust the pressure in the bucket cylinder rod end, move the bucket control lever to FULL BUCKET OPEN (rod retracted)

position. Check the pressure at tap (2).

4. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve pressure to 33 300 ± 1470 kPa (4850 ±

215 psi) using the same procedure as that described for the stick cylinder.

Adjustment (Boom Cylinder)

1. To adjust the pressure in the boom cylinder head end, move the boom control lever to FULL BOOM RAISE (rod extended)

position. Check the pressure in the boom cylinder head end at tap (2).

2. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve pressure in the same manner as described

for the stick cylinder.

3. To adjust the pressure in the boom cylinder rod end, move the boom control lever to FULL BOOM DOWN (rod retracted)

position. Check the pressure at tap (2).

4. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve pressure to 33 300 ± 1470 kPa (4850 ±

215 psi) using the same procedure as that described for the stick cylinder.

NOTE: Always make final pressure adjustments on the pressure rise.

NOTE: If an appropriate location is not available for full retraction of the boom cylinder, reverse the line relief valves of the head end and rod end by switching the valves. Adjust the pressure of the line relief valve now attached in the head end. Once adjusted, return the respective relief valves to their original positions and cancel the function of the service program "Calibration Mode". Refer to the section in the module, "Engine And Pump Electronic Control System, Calibration Mode Stop Procedure".

NOTE: After adjustment of the line relief valves, return the main relief pressure to its normal setting.

Travel Crossover Relief Valve Adjustment

Sprocket (Left Track) (15) Sprocket. (16) Stopper. Travel Brake Valve (Left Track) (17) Screw. (18)

Sprocket (Left Track) (15) Sprocket. (16) Stopper.

Sprocket (Left Track) (15) Sprocket. (16) Stopper. Travel Brake Valve (Left Track) (17) Screw. (18) Locknut.

Travel Brake Valve (Left Track) (17) Screw. (18) Locknut. (19) Crossover relief valve (reverse left travel). (20) Crossover relief valve (forward left travel).

travel). (20) Crossover relief valve (forward left travel). Pump Compartment (1) Tap (power shift pressure). (2)

Pump Compartment (1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).

Preparation

1. Start Service Program "Calibration Mode" and maintain power shift pressure at 2250 kPa (325 psi). Read the pressure gauge at

tap (1) for the power shift pressure settings.

NOTE: During this test, to prevent a change in power shift pressure do not turn the engine start switch to the OFF position.

2. Block forward left travel, by putting stopper (16) in position on the gear of sprocket (15), as shown above.

Adjustment Procedure

1. Slowly move the left travel control lever to FULL FORWARD position and check the pressure of crossover relief valve (20) at

tap (3).

2. Return the control lever to the NEUTRAL position and adjust relief valve pressure to 36 300 ± 1475 kPa (5250 ± 215 psi). To

adjust crossover relief valve (20), loosen locknut (18) and turn screw (17) until the pressure gauge at tap (3) reads 36 300 ± 1475

kPa (5250 ± 215 psi).

3. Tighten locknut (18) to a torque of 44 ± 5 N·m (33 ± 4 lb ft).

NOTE: Always make final pressure adjustments on pressure rise.

4. Position stopper (16) to block reverse left travel.

5. Slowly move the left travel control lever to FULL REVERSE position and check the pressure of crossover relief valve (19) at

tap (3). Adjust the pressure of crossover relief valve (19) in the same manner as described for crossover relief valve (20).

6.

Adjust the pressure of crossover relief valves of right travel motor in the same manner as described for the left travel motor. Use

the pressure gauge at tap (2) to read the pressure.

7. After completion of adjustment, stop the function of the service program "Calibration Mode". Refer to the section in the

module, "Engine And Pump, Electronic Control System, Calibration Mode Stop Procedure".

Main Relief Valve Adjustment

NOTE: Pressure adjustments to the main relief valve should be done by first adjusting the travel operation of the main relief valve and then adjusting the implement operation of the main relief valve. Any adjustment to the travel operation of the main relief valve will change the pressure setting to the implement operation of the main relief valve.

NOTE: Always make final pressure adjustments on pressure rise.

Always make final pressure adjustments on pressure rise. Top Of Main Control Valves (4) Plunger. (5)

Top Of Main Control Valves (4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.

Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve. Pump Compartment (1) Tap (power shift pressure).

Pump Compartment (1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).

Preparation

1. Place the machine on level ground and stop the engine.

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic System".

3. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (2).

4. Start the engine and place the engine speed dial at position "10" with the power mode selector switch at MODE III position.

5. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).

Adjustment Procedure (In Travel Operation)

5. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). Adjustment Procedure (In

Sprocket (Left Track) (15) Sprocket. (16) Stopper.

1. Block forward left travel by putting stopper (16) in position on the gear of sprocket (15).

2. Slowly move the left travel control lever to FULL FORWARD position and check main relief valve pressure at tap (3).

3. Return the control lever to the NEUTRAL position.

4. Loosen locknut (7) and turn adjuster (6) until the pressure gauge at tap (2) reads 34 300 ± 490 kPa (5000 ± 71 psi). Tighten

locknut (7) to a torque of 29 ± 2 N·m (22 ± 1 lb ft).

Reference: Turning adjuster (6) clockwise increases the pressure. Turning adjuster (6) counterclockwise decreases the pressure.

NOTE: Always make final pressure adjustments on pressure rise.

Adjustment Procedure (Implement Operation)

1. Slowly move the control lever to FULL BUCKET OPEN (bucket cylinder full retraction) position and check the main relief

valve pressure at tap (2).

2. Return the control lever to the NEUTRAL position and adjust main relief valve pressure to 31 400 ± 490 kPa (4550 ± 72 psi).

3. To adjust, loosen locknut (5) and turn plunger (4) until the pressure gauge at tap (3) reads 31 400 ± 490 kPa (4550 ± 72 psi).

Tighten locknut (5) to a torque of 29 ± 2 N·m (22 ± 1 lb ft).

Reference: Turning plunger (4) clockwise increases the pressure. Turning plunger (4) counterclockwise decreases the pressure.

NOTE: Always make final pressure adjustments on pressure rise.

Adjustment Of Automatic Travel Speed Travel Change Valve

Adjustment Of Automatic Travel Speed Travel Change Valve Preparation 1. Reset main relief valves. Refer to

Preparation

1. Reset main relief valves. Refer to the section, "Main Relief Valve Adjustment".

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic System".

system. See the section, "Release Of Pressure In The Hydraulic System". Pump Compartment (1) Tap (rear

Pump Compartment (1) Tap (rear pump).

3.

Install 49 000 kPa (7100 psi) pressure gauge at tap (1) of the rear pump.

kPa (7100 psi) pressure gauge at tap (1) of the rear pump. Pilot Oil Manifold Compartment

Pilot Oil Manifold Compartment (2) Tap (pilot pump delivery pressure).

4. Install 4750 kPa (700 psi) pressure gauge at tap (2).

4. Install 4750 kPa (700 psi) pressure gauge at tap (2). Travel Motor (Left Track) (3)

Travel Motor (Left Track) (3) Signal line.

5. Disconnect signal line (3) from the travel motor. Install a tee on the port that the signal line was removed from and connect

signal line (3) to tee. Attach a 4750 kPa (700 psi) pressure gauge to the tee.

6. Start the engine and raise the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).

7. Place the power mode selector switch in POWER MODE III position and maintain the maximum no load speed at 2180 ± 80

rpm with the AEC switch in the OFF position.

at 2180 ± 80 rpm with the AEC switch in the OFF position. Sprocket (Left Track)

Sprocket (Left Track) (4) Sprocket. (5) Stopper.

8. Block the forward left travel by putting stopper (5) in position on the gear of sprocket (4), as shown above.

9. Place the travel speed control switch in HIGH (rabbit) position.

10. The pressure gauge at tap (2) should read 3450 kPa (500 psi).

Adjustment Procedure

Pilot Oil Manifold Compartment (6) Automatic travel speed change valve. (A) Viewed from A side.

Pilot Oil Manifold Compartment (6) Automatic travel speed change valve. (A) Viewed from A side.

Automatic travel speed change valve. (A) Viewed from A side. Automatic Travel Speed Change Valve (Viewed

Automatic Travel Speed Change Valve (Viewed From A Side). (6) Automatic travel speed change valve. (7) Screw. (8) Locknut.

1. While reading the pressure gauges connected to the tee in signal line (3) and to tap (1), slowly move the left travel control

lever/pedal to the FORWARD position. When the pressure at tap (1) reads 31 700 ± 980 kPa (4600 ± 140 psi), the pressure gauge connected to signal line (3) should reduce to 0 kPa (0 psi).

NOTE: These pressures indicate that the automatic travel speed change valve has caused the travel motor to shift to low (turtle) speed.

2. Slowly return the left travel control lever/pedal to the NEUTRAL position.

3. If the pressure gauge connected to signal line (3) does not read 0 kPa (0 psi) at the time the system pressure at tap (1) reads 31

700 ± 980 kPa (4600 ± 140 psi), then adjust automatic travel speed change valve (6) as follows:

NOTE: Always make final pressure adjustments on pressure rise.

a. Loosen locknut (8) and turn screw (7) until the pressure gauge connected to line (3) reads 0 kPa (0 psi) when the pressure gauge at tap (1) reads 31 700 ± 980 kPa (4600 ± 140 psi).

b. Tighten locknut (8) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).

NOTE: Turning screw (7) clockwise increases the pressure. Turning screw (7) counterclockwise decreases the pressure.

4. Repeat Step 1.

5. Slowly move the travel control lever/pedal towards the NEUTRAL position until the pressure gauge at tap (1) decreases to 13

700 ± 490 kPa (2000 ± 71 psi). Now the pressure gauge connected to signal line (3) will read 3450 kPa (500 psi).

NOTE: These pressures indicate when the automatic travel speed change valve causes the travel motor to shift to high (rabbit) speed.

Pump Flow Tests

Pump Flow Tests Controller Compartment (1) Controller alarm lamp. (2) Controller. Right Console (3) Monitor. (4)

Controller Compartment (1) Controller alarm lamp. (2) Controller.

Compartment (1) Controller alarm lamp. (2) Controller. Right Console (3) Monitor. (4) Monitor panel. NOTE: Before

Right Console (3) Monitor. (4) Monitor panel.

NOTE: Before starting pump flow tests, check the action alarm indicators on controller (2) and monitor panel (4). If the action alarm indicators indicate a normal condition, then perform the operational tests.

NOTE: If operational tests (for example, cycle times) indicates that a slow implement problem is common to the circuits of one pump, then the problem is most likely in the hydraulic system. The "Pump Flow Tests" should then be performed.

NOTE: If the operational tests indicate an implement speed problem common to both pump circuits, then the engine, fuel, or working altitude may be the problem.

Main Pump Constant Horsepower Control Test

Illustration Of Flow Meter Tool Layout (Constant Horsepower Control Test) (Main Pump) (1) Portable hydraulic
Illustration Of Flow Meter Tool Layout (Constant Horsepower Control Test) (Main Pump) (1) Portable hydraulic

Illustration Of Flow Meter Tool Layout (Constant Horsepower Control Test) (Main Pump) (1) Portable hydraulic tester (flow meter). (2) O-ring seal. (3) Sleeve. (4) O-ring seal. (5) Nipple. (6) Coupler. (7) Coupling. (8) Sleeve. (9) Hose. (10) Elbow. (11) O-ring seal. (12) Plug. (13) Tee. (16) Outlet line (front pump). (17) Outlet line (rear pump). (14) Front pump. (15) Rear pump. (18) Makeup line. (19) Swing motor.

Preparation (Front Pump)

Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Front Pump) (1) Portable hydraulic tester

Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Front Pump) (1) Portable hydraulic tester (flow meter). (12) Plug (front pump delivery line). (16) Outlet line (front pump). (17) Outlet line (rear pump). (14) Front pump. (15) Rear pump. (18) Makeup line. (19) Swing motor. (21) Main control valves. (22) Pressure gauge. (23) Tap (front pump). (24) Tap (power shift pressure). (25) Tap (rear pump). (26) Engine. (20) Multitach.

(25) Tap (rear pump). (26) Engine. (20) Multitach. Pump Compartment (9) Hose. (12) Plug. (14) Front

Pump Compartment (9) Hose. (12) Plug. (14) Front pump. (15) Rear pump. (16) Outlet line (front pump). (23) Tap (front pump). (24) Tap (power shift pressure). (25) Tap (rear pump).

(24) Tap (power shift pressure). (25) Tap (rear pump). Swing Motor Compartment (Top View) (13) Tee.

Swing Motor Compartment (Top View) (13) Tee. (19) Swing motor.

Flow Meter (1) Portable hydraulic tester (flow meter). (9) Hose. (20) Multitach. (27) Valve (flow

Flow Meter (1) Portable hydraulic tester (flow meter). (9) Hose. (20) Multitach. (27) Valve (flow meter).

meter). (9) Hose. (20) Multitach. (27) Valve (flow meter). To prevent personal injury or equipment damage

To prevent personal injury or equipment damage from failure of the flow meter or associated circuit components because of blocked pump flow, make sure before starting the engine that the flow meter valve is fully open (turned counterclockwise).

flow meter valve is fully open (turned counterclockwise). 1. Position the machine on level ground and

1. Position the machine on level ground and stop the engine.

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic System".

3. Install the following tools in accordance with flow meter tool layout illustration and circuit diagram:

a. Disconnect outlet line (16) from front pump (14).

b. Install plug (12) and O-ring seal (11) to the end of outlet line (16).

c. Disconnect makeup line (18) from the connector of swing motor (19).

d. Install tee (13) and two O-ring seals (11) to the connector. Connect makeup line (18) and O-ring seal (11) to tee (13).

e. Connect portable hydraulic tester (flow meter) (1) between front pump (14) and tee (13).

f. Install pressure gauge (22) at power shift pressure tap (24). Install pressure gauge (22) at front pump tap (23). Tap (24) is

used to measure the power shift pressure. Tap (23) is used to measure the front pump delivery pressure.

NOTE: A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (22).

g. Install multitach group (20) on engine (26). This is used to read engine speed.

4. Start the engine and place the power mode selector switch in MODE III position.

5. Place the engine speed dial at position "10" and maintain the maximum no load speed at 2180 ± 80 rpm with the AEC switch

OFF. (Read the rpm three seconds elapsed time after the engine speed dial has been placed in position "10").

6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil temperature, move the stick in and out its full

travel several times.

Preparation (Rear Pump)

Pump Compartment (12) Plug (rear pump outlet line). (15) Outlet line (rear pump). (17) Rear

Pump Compartment (12) Plug (rear pump outlet line). (15) Outlet line (rear pump). (17) Rear pump. (26) Tap (rear pump).

Perform the same preparation as that described for the front pump flow test under constant horsepower control except Step 3. Use the following procedure in replacement for Step 3, for the rear pump (15):

a. Disconnect outlet line (17) from rear pump (15).

b. Install plug (12) and O-ring seal (11) to the end of outlet line (17).

c. Disconnect makeup line (18) from the connector of swing motor (19).

d. Install tee (13) and two O-ring seals (11) to the connector. Connect makeup line (18) and O-ring seal (11) to tee (13).

e. Connect flow meter (1) between rear pump (15) and tee (13).

f. Install pressure gauge (22) at power shift pressure tap (24). Install pressure gauge (22) at rear pump tap (25). Tap (24) is used to

measure the power shift pressure. Tap (25) is used to measure the rear pump delivery pressure.

NOTE: A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (22).

g. Install multitach group (20) on engine (26).

Test Procedure

NOTE: Perform the front and rear pump flow tests one at a time.

Perform the front and rear pump flow tests one at a time. To prevent personal injury

To prevent personal injury or equipment damage from failure of the flow meter or associated circuit components because of blocked pump flow, make sure before starting the engine that the flow meter valve is fully open (turned counterclockwise).

flow meter valve is fully open (turned counterclockwise). To prevent personal injury and/or equipment damage from
flow meter valve is fully open (turned counterclockwise). To prevent personal injury and/or equipment damage from

To prevent personal injury and/or equipment damage from failed lines or components while the flow meter is returned to the open flow position after a flow test, slowly open the flow meter valve and monitor pump flow at the same time to make sure flow increases. If pump flow does not increase as the flow meter is opened, shut the engine off and determine what is causing the pump not to upstroke.

off and determine what is causing the pump not to upstroke. 1. With the engine running,

1. With the engine running, start the service program "Calibration Mode" and maintain the power shift pressure at a constant pressure of 1850 ± 50 kPa (270 ± 7 psi). The power shift pressure is read at tap (24), using pressure gauge (22).

NOTE: During this test, do not turn the starter switch to the OFF position to prevent any change in power shift pressure. See the section "Calibration Mode Stop Procedure".

NOTE: To start service program "Calibration Mode" see the section "Calibration Mode Start-Up" in the manual, "Engine And

Pump Electronic Control System, System Operation, Testing And Adjusting".

2. Slowly turn valve (27) of portable hydraulic tester (1) clockwise and record pump flow at each of the following pressure points.

Use pressure gauge (22) at tap (23) or (25) for this pressure reading.

gauge (22) at tap (23) or (25) for this pressure reading. P-Q Characteristic Curve NOTE: Flow

P-Q Characteristic Curve

or (25) for this pressure reading. P-Q Characteristic Curve NOTE: Flow specifications given above are based

NOTE: Flow specifications given above are based on an engine speed of 2100 rpm. To get more accurate test results, each of measurements should be corrected by calculating as follows:

Flow corrected = (Flow measured × 2100) ÷ rpm measured

1. Any flow readings must be done only in upstroke.

2. The pump flow changes approximately 5.5 liter/min (1.5 U.S. gpm) for each 98 kPa (15.5 psi) of power shift pressure.

Negative Flow Control Test

Illustration Of Flow Meter Tool Layout (Negative Flow Control Test) (Main Pumps) (1) Portable hydraulic

Illustration Of Flow Meter Tool Layout (Negative Flow Control Test) (Main Pumps) (1) Portable hydraulic tester (flow meter). (2) O-ring seal. (3) Adapter block. (4) O-ring seal. (5) Nipple. (6) Coupler. (7) Reusable coupling. (8) Sleeve. (9) Hose. (10) Elbow. (11) O-ring seal. (12) Plug. (13) Tee. (14) Front pump. (15) Rear pump. (16) Outlet line (front pump). (17) Outlet line (rear pump). (18) Makeup line. (19) Swing motor.

Preparation (Front Pump)

(16) Outlet line (front pump). (17) Outlet line (rear pump). (18) Makeup line. (19) Swing motor.

Circuit Diagram For Negative Flow Control Test (Front Pump) (1) Portable hydraulic tester (flow meter). (9) Hose. (12) Plug (front pump delivery line). (14) Front pump. (15) Rear pump. (16) Delivery line (front pump). (17) Delivery line (front pump). (19) Swing motor. (20) Main control valves. (21) Negative flow control line. (22) Pressure gauge. (23) Tap (front pump). (24) Pilot oil manifold. (25) Tap (rear pump). (26) Tap. (27) Tee. (28) Test hose. (29) Plug. (30) Pressure gauge. (31) Engine. (32) Multitach. (33) Negative flow control line.

Engine. (32) Multitach. (33) Negative flow control line. Pump Compartment (9) Hose. (12) Plug. (14) Outlet

Pump Compartment (9) Hose. (12) Plug. (14) Outlet line (front pump). (21) Negative flow control line (front pump). (23) Tap (front pump).

flow control line (front pump). (23) Tap (front pump). Illustration Of Tool Layout (Negative Flow Control

Illustration Of Tool Layout (Negative Flow Control Test)(Main Pump) (24) Pilot oil manifold. (26) Tap. (27) Tee. (28) Test hose. (29) Plug. (30) Pressure gauge. (36) Coupler. (37) Nipple. (38) O-ring. (39) Coupler. (40) Elbow (to negative flow control port).

(30) Pressure gauge. (36) Coupler. (37) Nipple. (38) O-ring. (39) Coupler. (40) Elbow (to negative flow

Portable Hydraulic Tester (Flow Meter) (1) Portable hydraulic tester (flow meter). (22) Pressure guage. (32) Multitach. (34) Valve (flow meter).

Pressure guage. (32) Multitach. (34) Valve (flow meter). Swing Motor Compartment (9) Hose. (13) Tee. (18)

Swing Motor Compartment (9) Hose. (13) Tee. (18) Make up line. (19) Swing motor.

(9) Hose. (13) Tee. (18) Make up line. (19) Swing motor. Pilot Oil Manifold Compartment (24)

Pilot Oil Manifold Compartment (24) Pilot oil manifold. (26) Tap. (35) Pilot relief valve.

1. Position the machine on level ground and stop the engine.

2. Release the pressure in the hydraulic system. See the section in this module "Release Of Pressure In The Hydraulic System".

3. Install the following tools in accordance with flow meter tool layout illustration and circuit diagram:

a. Disconnect outlet line (16) from front pump (14).

b. Install plug (12) and O-ring seal (11) to the end of outlet line (16).

c. Disconnect makeup line (18) from the connector of swing motor (19).

d. Install tee (13) and O-ring seal (11) to the connector. Connect makeup line (18) and O-ring seal (11) to tee (13).

e. Connect portable hydraulic tester (1) between front pump (14) and tee (13).

f. Disconnect negative flow control line (21) from front pump (14) and install plug (29) in the open end of negative flow

control line (21).

g. Install tee (27) to elbow (40).

h. Connect hose (28) between tee (27) and tap (26) of pilot oil manifold (24).

i. Install pressure gauge (22) at front pump tap (23). A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (22). Tap (23) is used to measure the front pump delivery pressure.

j. Install pressure gauge (30) to tee (27). A 4900 kPa (700 psi) pressure gauge can be used in place of pressure gauge (30).

k. Install multitach group (32) on engine (31).

4. Start the engine and place the power mode selector switch in MODE III position.

5. Place the engine speed dial at position "10" and maintain the maximum no load speed at 2180 ± 80 rpm with the AEC switch

OFF. (Read the rpm three seconds elapsed time after the engine speed dial has been placed in position "10").

6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil temperature, move the stick in and out its full travel several times.

Preparation (Rear Pump)

out its full travel several times. Preparation (Rear Pump) Pump Compartment (9) Hose. (12) Plug (rear

Pump Compartment (9) Hose. (12) Plug (rear pump outlet line). (15) Outlet line (rear pump). (25) Tap (rear pump). (35) Negative flow control line (rear pump).

Perform the same preparation as that described for the front pump flow test under constant horsepower control except Step 3. Use the following procedure in replacement for Step 3, for the rear pump (15):

a. Disconnect outlet line (17) from rear pump (15).

b. Install plug (12) and O-ring seal (11) to the end of outlet line (17).

c. Disconnect makeup line (18) from the connector of swing motor (19).

d. Install tee (13) and O-ring seal (11) to the connector. Connect makeup line (18) with O-ring seal (11) to tee (13).

e. Connect portable hydraulic tester (1) between rear pump (15) and tee (13).

f. Disconnect negative flow control line (33) from rear pump (15) and install plug (29) in the open end of negative flow control

line (33).

g. Install tee (27) to elbow (40).

h. Connect hose (28) between tee (27) and tap (26) of pilot oil manifold (24).

i. Install pressure gauge (22) at rear pump tap (25). A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (22). Tap (25) is used to measure the rear pump delivery pressure.

j. Install pressure gauge (30) to tee (27). A 4900 kPa (700 psi) pressure gauge can be used in place of pressure gauge (30).

k. Install multitach group (32) on engine (31). This is used to read engine speed.

Test Procedure

NOTE: Perform the front and rear pump negative flow control tests one at a time.

and rear pump negative flow control tests one at a time. To prevent personal injury or

To prevent personal injury or equipment damage from failure of the flow meter or associated circuit components because of blocked pump flow, make sure before starting the engine that the flow meter valve is fully open (turned counterclockwise).

flow meter valve is fully open (turned counterclockwise). To prevent personal injury and/or equipment damage from
flow meter valve is fully open (turned counterclockwise). To prevent personal injury and/or equipment damage from

To prevent personal injury and/or equipment damage from failed lines or components while the flow meter is returned to the open flow

position after a flow test, slowly open the flow meter valve and monitor pump flow at the same time to make sure flow increases. If pump flow does not increase as the flow meter is opened, shut the engine off and determine what is causing the pump not to upstroke.

off and determine what is causing the pump not to upstroke. 1. Place the power mode

1. Place the power mode selector switch to MODE III position.

2. Slowly turn valve (34) of portable hydraulic tester (1) clockwise until the pump delivery pressure setting is 6850 kPa (1000 psi).

3. Adjust pilot relief valve (35) of pilot oil manifold (24) until pressure gauge (30) connected to tee (27) reads 2350 kPa (340 psi).

4. Record the negative control flow at each of the following pressure points:

control flow at each of the following pressure points: NOTE: Flow specifications given above are based

NOTE: Flow specifications given above are based on an engine speed of 2100 rpm. To get more accurate test results, measured flow should be corrected by calculating as follows:

Flow corrected = (Flow measured × 2100) ÷ rpm measured

P-Q Characteristic Curve [Negative Flow Control at 6850 kPa (1000 psi) Pump Delivery Pressure] Pump

P-Q Characteristic Curve [Negative Flow Control at 6850 kPa (1000 psi) Pump Delivery Pressure]

Pump Flow Adjustment

If the flow measurements are out of specification, adjust the flow using the following procedures:

NOTE: Any flow variation per one turn of a setscrew should be used as a guide only. Always use a portable hydraulic tester to adjust the pump flow.

Flow Adjustment Under Constant Horsepower Control

pump flow. Flow Adjustment Under Constant Horsepower Control Main Pump (1) Setscrew. (2) Locknut. (3) Setscrew.

Main Pump (1) Setscrew. (2) Locknut. (3) Setscrew. (4) Locknut. (5) Locknut. (6) Setscrew. (7) Setscrew. (8) Setscrew. (9) Setscrew.

Flow adjustment procedure for the front and rear pumps under constant horsepower control is the same. Setscrew (3) and (8) are for the lower pressure range where the first stage spring in each pump regulator activates. Setscrews (1) and (9) are for the higher

pressure range where the second stage spring in each regulator activates.

Front Pump Adjustment

1. Loosen locknut (4).

2. Turn setscrew (3) until adjusted to the correct specification.

Turning setscrew (3) 1/4 turn clockwise increases the flow rate approximately 10.7 liter/min (2.8 U.S.gpm) at a system pressure of

13

700 kPa (2000 psi) and 17 700 kPa (2550 psi) where the first stage spring activates.

3.

Tighten locknut (4) to a torque of 155 ± 20 N·m (115 ± 15 lb ft).

4.

Loosen locknut (2).

5.

Turn setscrew (1) until adjusted to the correct specification.

Turning setscrew (1) 1/4 turn clockwise increases the flow rate approximately 4.8 liter/min (1.3 U.S.gpm) at a system pressure of

23

500 kPa (3400 psi) and 29 400 kPa (4250 psi) where the second stage spring activates.

6.

Tighten locknut (2) to a torque of 16 ± 2 N·m (12 ± 1 lb ft).

Rear Pump Adjustment

To adjust the rear pump flow under constant horsepower control do the same as that described above using setscrews (8) and (9).

Maximum Flow Adjustment

Maximum flow adjustment procedure for front and rear pumps is the same. Use setscrew (6) for the front pump and setscrew (7) for the rear pump.

1. Loosen locknut (5).

2. Turn setscrew (6) until adjusted to the correct specification. Turning the setscrew 1/4 turn clockwise decreases flow rate

approximately 3.0 liter/min (.8 U.S.gpm).

3. Tighten locknut (5) to a torque of 130 ± 10 N·m (95 ± 7 lb ft).

Negative Flow Control Adjustment

a torque of 130 ± 10 N·m (95 ± 7 lb ft). Negative Flow Control Adjustment

Pump Compartment (43) Locknut. (44) Setscrew.

Rear Pump (Viewed From Drive Shaft Side) (45) Setscrew. Negative flow control adjustment procedure for

Rear Pump (Viewed From Drive Shaft Side) (45) Setscrew.

Negative flow control adjustment procedure for front and rear pumps is the same. Use setscrew (45) for the front pump and setscrew (44) for the rear pump.

1. Loosen locknut (43).

2. Turn setscrew (44) until adjusted to the correct specification.

Turning the setscrew 1/4 turn clockwise increases the flow rate approximately 7.8 liter/min (2.1 U.S.gpm) at a negative control pressure of 2450 kPa (355 psi).

3. Tighten locknut (43) to a torque of 16 ± 2 N·m (12 ± 1 lb ft).

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