Serv

Service Training
Instructor Module SERV2723

April 2002
TECHNICAL INSTRUCTION MODULE
330C HYDRAULIC EXCAVATOR

HYDRAULIC SYSTEMS
SERV2723 Instructor Module
04/02 Table of Contents
TABLE OF CONTENTS
MODULE DESCRIPTION
PREPARATION CHECKLIST
MODULE PREREQUISITES
MODULE LESSON PLAN
MODULE OBJECTIVES
TEXT REFERENCE
LABORATORY EXERCISES
CASE STUDIES
POSTTEST
04/02 Module Description
MODULE DESCRIPTION
CONTENT This module is designed to introduce the student to the hydraulic systems
on the 330C Hydraulic Excavator. Emphasis is placed on the operation,
function and adjustments of the hydraulic systems.
After completing this module, the student will have a good understanding
of the hydraulic systems and hydraulic system component functions on
the 330C Hydraulic Excavator. The module contains laboratory
exercises, handouts and instructions for setting up a class.
AUDIENCE Level II–Field service personnel, resident mechanics, technical
communicators and shop technicians. All students should have some
overall experience with Caterpillar equipment and have a basic working
knowledge of servicing hydraulic systems.
INSTRUCTOR NOTE This technical presentation may have modifications to the content
after publication. Please check the Service Training Web Site
(https://psmktg.cat.com/srvtrng/new/nmater/) for the updates.
For additional material that may be useful check the Media Search
Web Site (http://logistics-cf.cat.com/media/dealers/extranet.cfm).
NOTE: The materials listed as references are for the 330C Hydraulic
Excavator S/N DKY1-Up. For all other models the instructor should
refer to SIS for the appropriate materials or service manual module
media number.
REFERENCES Service Manual Modules Form No.

330C Excavator Hydraulic System Specifications RENR5433
330C Excavator Hydraulic Systems Operation, RENR5434
330C Excavator Hydraulic Systems Testing and Adjusting RENR5435
330C Excavator Hydraulic Schematic (Std. Config.) RENR5437
330C Excavator Electrical System Schematic RENR5457
330C Excavator Operation and Maintenance Manual SEBU7445
312C, 315C, 320C, 322C, 325C and 330C Excavators
Engine and Pump Control System Operation, Testing
and Adjusting RENR3814
320C, 322C, 325C and 330C Excavators Tool Control
System, Systems Operation, Troubleshooting, Testing
and Adjusting Module RENR3823
C9 Engine Specifications SENR9500
C9 Engine Systems Operation, Testing and Adjusting SENR9501
C9 Engine Troubleshooting Guide SENR9506
SERV2723 -2- Instructor Module
04/02 Module Description
REFERENCES Parts Manual

330C Excavator Parts Manual SEBP3366
SUPPLEMENTAL Video Tape

MATERIAL
320C Orientation TEVN4803
300C Monitoring System Overview SEVN5126
CD ROM
"C" Series Hydraulic Excavator Monitor Simulator AERC0436
Service Training Meeting Guides
STMG 697 "300 B Series Hydraulic Excavator, Hydraulic

System Operation" SESV1697
CD ROM version of STMG1697 SERV1697
STMG 620 "320/330 Hydraulic Excavators, Hydraulic
Systems Operation" SESV1620
Technical Instruction Modules
"300C Hydraulic Excavators, Electronic Control Systems" SERV2693
Miscellaneous
Programmed Instruction Course "Basic Electricity" SEBV0534

Pocket Diagnostic Card NEEG2500
Booklet "Caterpillar Service Tool Software/Getting Started"
(Includes Caterpillar Electronic Technician Software,
call order analyst to confirm) JEBD3003
Booklet "Caterpillar Service Tool Software/User’s Manual"
(Includes Caterpillar Electronic Technician,
Dealer Additions Software) NEHS0716
320C/320B Comparative Bulletin TEJB7010
Specalog "320C Hydraulic Excavator" AEHQ5393
04/02 Preparation Checklist
PREPARATION CHECKLIST
MODULE Prior to conducting the training session, gather the following materials for
PREPARATION the machine being used:
Text Reference Materials
330C Excavator Hydraulic Systems Operation RENR5434
330C Excavator Hydraulics Testing and Adjusting RENR5435
312C, 315C, 320C, 322C, 325C and 330C
Excavators Engine and Pump Control Systems
Operation, Testing and Adjusting RENR3814
Student Materials (theirs to keep)

330C Excavator Hydraulic Systems Operation RENR5434
330C Excavator Hydraulics Testing and Adjusting RENR5435
312C, 315C, 320C, 322C, 325C and 330C
Excavators Engine and Pump Control Systems
Operation, Testing and Adjusting RENR3814
330C Excavator Electrical System Schematic RENR5457
330C Excavator Hydraulic Schematic (Std. Config.) RENR5437
Instructor and Student Reference Materials - at least one copy of the

following materials should be available for class and lab use.
330C Excavator Service Manual (complete) RENR5450
330C Hydraulic Excavator Parts Book SEBP3366
Booklet "ET Service Tool Software/Getting Started"
(includes Electronic Technician Self Study Course) JEBD3003
List of Acronyms and Glossary of Electrical/Electronic
Terms SEKV3001
Pocket Diagnostic Card NEEG2500
C9 Basic Engine Specifications SENR9500
C9 Basic Engine Systems
Operation, Testing and Adjusting SENR9501
320C, 322C 325C and 330C Excavators Tool
Control System System Operation,
Troubleshooting, and Testing and Adjusting RENR3823
Video Tape
320C Orientation TEVN4803
300C Monitoring System Overview SEVN5126
PREPARATION CHECKLIST (continued)
LABORATORY Prior to delivering the classroom training session, perform the following
PREPARATION steps:
Review the Lesson Plan to become familiar with the flow of the
training session.
Review the Objectives to become familiar with the expected
results.
Review the Service Manual modules (Forms RENR5434,
RENR5435, and RENR3814) to become familiar with the topics.
Duplicate sufficient Student Material for the class.
Prior to delivering the lab exercises perform the following steps:
Review the Laboratory Exercises section.
Prepare a machine for the class.
Reserve two mechanic's tool boxes with hand tools (include metric).
Gather the following special tools and fittings:

1 - Electronic Service Tool [Laptop Computer with the latest
Electronic Technician software installed (Form JEBD3003)]
1 - 1U6602 Phototach (or 6V2100 Multitach Group or 9U7401
Multitach
1 - FT2542 Track Block Assembly
1 - 8T0470 Thermometer Group (or 4C9500 Digital Thermometer)
8 - 4C6481 Coupler Assembly
8 - 4C6482 Nipple Assembly
8 - 4C8767 Coupling
1 - 4C9910 Portable Hydraulic Tester (flow meter)
2 - 4I6141 Coupling Assembly
4 - 3J1907 O-ring Seal
16 - 5K9090 O-ring Seal
18 - 6K6307 O-ring Seal
8 - 7M8485 O-ring Seal
4 - 8C9026 Adapter
2 - 1P3703 Rectangular Seal
1 - 5P3277 Measuring Tape
Stopwatch
Remote Drain Hose, inside diameter 20 mm (0.78 in)
Scale 150 mm (6 in)
Gather the following special tools and fittings (continued):

4 - 5P0201 Hose
8 - 5P1010 Sleeve
8 - 8T4184 Bolt
8 - 8T4223 Hard Washer
1 - 8T5082 Union
2 - 1U8292 Adapter
2 - 1U8303 Fitting
2 - 9U7335 Blocking Cover
2 - 6V0400 Half Flange
2 - 6V8716 Seal Connector
2 - 8T0855 Gauge [4000 kPa (580 psi)]
2 - 8T0856 Gauge [6000 kPa (870 psi)]
3 - 8T0861 Gauge [60000 kPa (8700 psi)]
4 - 8T8902 Tee (3/8 in. ORFS w/9/16 in. SAE thd. tap)
5 - 6V3014 Hose
2 - 6V3965 Nipple, Valved (w/9/16 in. SAE ext. thd.)
5 - 6V3989 Nipple, Open (w/1/4 in. NPTF int. thd.)
10 - 6V4143 Coupler, Valved (w/1/8 in. NPTF int. thd.)
8 - 6V8397 O-ring Seal
6 - 6V9829 Cap
2 - 6V9830 Cap Assembly
1 - 6V9840 Swivel Tee
1 - 6V9832 Cap
2 - 6V9854 Swivel Elbow
The following fittings are required to attach the flow meter to the boom
cylinder lines below the boom cylinders:
2 - 8T1685 Tee
5 - 5P9757 O-ring Seal
2 - 4C6482 Nipple
2 - 7M8485 O-ring Seal
Machine Requirements
1 - 320C, 322C, 325C or 330C Hydraulic Excavator

04/02 Module Prerequisites
MODULE PREREQUISITES
PREREQUISITES All students should have some overall experience with Caterpillar
equipment and have a basic working knowledge of servicing hydraulic
systems.
PREREQUISITE TESTS Prerequisite tests should be administered at least a few weeks before the
participants take the course.
Participants should pass the following pretests with a score of 90% or
better:
Graphic Fluid Power Symbols Pretest SEBV0556
Basic Hydraulics Pretest SEBV0557
Machine Electrical Pretest SEBV0558
If a participant does not accomplish 90% or better, identify the area of

deficiency and then refer to the pretest for the recommended course or
courses for the student to review. After ample review time, the student
should retake the test.
PREREQUISITE These prerequisite courses should be completed prior to participating in

COURSES this course.
Interactive Video Course "Fundamentals
of Mobile Hydraulics" (CD ROM) TEMV9001
Interactive Video Course "Fundamentals
of Electrical Systems" (CD ROM) TEMV9002
PRIOR TRAINING Prior training in electrical, hydraulics and Caterpillar engines will also be
beneficial. Examples of this training are:
1. Has completed the Technical Instruction Module "365B Hydraulic
Excavator--Hydraulic Systems Operation" (Form SERV2671).
2. Has viewed the Video Tape "320C Hydraulic Excavator
Orientation" (Form TEVN4803) and has a basic familiarity with the
320C Hydraulic Excavator component locations.
04/02 Lesson Plan
INSTRUCTOR TIPS:
Provide each student MODULE LESSON PLAN
with a printed copy of
the course description
and objectives.
Time Estimates
• General Information Module Objectives
Discuss objectives and class schedule
Hand out and discuss student material 30 min
• Pilot System Visual Presentation: Pilot System and Components 30 min

Lab A: Locate and Identify Pilot System Components 20 min
Students locate and identify components on the "C" Series hydraulic
excavator pilot system.
Lab B: Test and Adjust Pilot System Relief Valve 10 min

Students conduct testing and adjusting procedures on the pilot system
relief valve.
• Pump System Visual Presentation: Implement/Travel Pumps

and Pump Components 90 min
Lab C: Locate and Identify Implement/Travel Pumps

and Pump Components 30 min
excavator implement/travel pumps.
Lab D: Test and Adjust Implement/Travel Pumps:

Constant Horsepower Controls (Flow meter) 180 min
Pump Negative Flow Controls 60 min
Students conduct testing and adjusting procedures for pump flow
output for the implement/travel pumps.
• Main Control Valve Visual Presentation: Main Control Valve and

• Boom System Pressure Regulation 90 min
• Stick System
• Bucket System
04/02 Lesson Plan
MODULE LESSON PLAN (continued)
Lab E: Locate and Identify Main Control Valve and

Main Control Valve Components 30 min
excavator main control valve group.
Lab F: Test and Adjust Main Relief Valve and Implement Line Relief
Valves:
Main Relief Valve 20 min
Line Relief Valves 30 min
Students conduct testing and adjusting procedures for pump flow
output for the main relief valve and the line relief valves.
• Travel System Visual Presentation: Travel System, Final Drives and Swivel 40 min
Lab G: Locate and Identify Travel System, Final Drives

and Swivel Components 30 min
Students locate and identify components on the "C" Series
hydraulic excavator travel system, final drives, and swivel
components.
Lab H: Test and Adjust Travel System

Crossover Relief Valves 60 min
Test Travel Motor Case Drain Flow 30 min
Students conduct testing and adjusting procedures for the
crossover relief valves for the travel systems and measure
the case drain for the travel motors.
• Swing System Visual Presentation: Swing System and Components 60 min
Lab I: Locate and Identify Swing System Components 30 min

Students locate and identify components on the "C" Series
hydraulic excavator travel system, final drives, and swivel
components.
04/02 Lesson Plan
MODULE LESSON PLAN (continued)
Lab J: Test and Adjust Swing System

Test and Adjust Swing System Relief Valves 30 min
Test Swing Motor Case Drain Flow 30 min
Test and Adjust Swing Brake Solenoid 30 min
Students conduct testing and adjusting procedures for the crossover
relief valves for the swing system and measure the case drain for the
swing motor. The students will also perform the testing and adjusting
procedure for the swing brake solenoid.
• Return System Visual Presentation: Cooling and Return Systems

and Components 30 min
Lab K: Locate and Identify Cooling and Return Systems

Components 30 min
excavator cooling and return system components.
• Case Study Case Study 60 min
• Posttest Posttest 30 min
• Review Review Posttest, Question and Answer Period 30 min
Total Estimated Time 19 hours

04/02 Module Objectives
MODULE OBJECTIVES
After completion of this module, the student will be able to:

1. Given a machine locate and identify during lab exercises:
A. The pilot system components using Lab A Worksheets.
B. The implement pumps and pump components using Lab C
Worksheets.
C. The main control valve components using Lab E Worksheets.
D. The cylinders, travel system, final drives, and swivel using Lab G
Worksheets.
E. The swing system components using Lab I Worksheets.
F. The return system components using Lab K Worksheets.
2. Given a machine and the appropriate service literature perform the

following tests during a lab exercises. All pressures and flows must
be within the Service Manual Specifications:
A. Test and adjust the pilot system relief valve using Lab B
Worksheet.
B. Test and adjust the travel/implement pump constant horsepower
controls and test and adjust the implement/travel pump negative
flow controls using Lab D Worksheets.
C. Test and adjust the implement line relief valves and test and
adjust the main relief valve using Lab F Worksheets.
D. Test and adjust the travel crossover relief valves and measure the
travel motor case drain flow using Lab H Worksheets.
E. Test and adjust the swing system relief valves, measure the swing
motor case drain flow, and test the swing brake solenoid valve
using Lab J Worksheets.
3. Given all reference material and class notes:

A. Correctly identify potential system problems caused by an
improperly operating hydraulic system during a case study.
04/02 Module Objectives
MODULE OBJECTIVES (continued)
4. Given all reference material and class notes, on a posttest:

A. Correctly answer true or false statements regarding hydraulic
system operation.
B. Correctly fill in the blanks regarding hydraulic system pressures.
C. Correctly match the function to the corresponding hydraulic
system component.
04/02 Text Reference
TEXT REFERENCE
INSTRUCTOR NOTE This Technical Instruction Module does not contain the traditional
Slide/Text Reference included in earlier modules. Instead, the Service
Manual module "330C Excavator Hydraulic Systems Operation" (Form
RENR5434) must be used for preparation and self study. The included
visual list and suggested Lesson Plan serve as a guide through the Service
Manual module.
The presentation is separated into corresponding sections covering the
different hydraulic pumps and hydraulic systems. Lab exercises provide
the student with an opportunity to locate and identify the hydraulic pumps
and hydraulic system components and perform testing and adjusting
procedures on selected components and systems.
Cross Reference for Service Manual Pages and Visuals

Topic Pages Visuals
Introduction 1 - 10 1-7
Pilot System and Components 10 - 27 8 - 29
Implement/Travel Pumps and

Pump Components 28 - 38 30 - 41
Main Control Valve, Pressure

Regulation and Proportional Priority
Pressure Compensation 38 - 63 42 - 63
Boom, Stick and Bucket Components 63 - 91 64 - 90
Travel System, Final Drive and

Swivel Components 91 - 122 91 - 120
Swing System and Components 122 - 151 121 - 147
Return System and Components 151 - 157 148 - 159

04/02 Laboratory Exercises
LABORATORY EXERCISES
INSTRUCTOR NOTE The following section provides lab exercises to reinforce the presentation.
The section provides directions to set up, facilitate and assist during the
student lab exercises.
Some lab exercises are paper and pencil (worksheets) while other labs are
"hands on" labs. Answers are provided for the worksheet exercises.
The actual student lab sheets along with accompanying materials are
located in the Student Materials section.
Review and perform the labs before delivering this module.
At the beginning of each lab, have all students review the lab description
to be sure the students understand what to do.
NOTE: Discuss safety procedures with the students for each shop lab
exercise (i.e. safety glasses, clothing).
Lab A: Locate and Identify Pilot System Components
INSTRUCTOR NOTE Shop Lab Exercise:
Lettered or numbered tags should be made up and placed on the pilot

system components by the instructor. The students can then place the
correct number or letter on the blank next to the component name on the
worksheets. Refer to the handout included to help identify the component
locations on the machine.
Instructor should review latest parts information to complete the
worksheets prior to the start of class.
INDIVIDUAL OR GROUP Procedure:

EXERCISE
Explain to the class how to fill out the worksheets.
During the presentation, the worksheets should be used to take notes as
the function of each component is explained.
The parts manual should be used in the classroom to locate and identify
components and their respective part numbers prior to machine
component identification.
Have the class identify each component on the machine.
Underlined words appear as blanks on Student Materials. Students are
required to fill in the missing text.
After the completion of this exercise discuss the completed worksheets
with the students.
MATERIALS NEEDED Lab A Worksheets
A 330C Hydraulic Excavator with the pilot system components

tagged
Tags
Appropriate Parts Manual (or SIS)

Lab A Worksheet 1
Locate and Identify Pilot System Components
INSTRUCTOR NOTE: Fill in the appropriate letters or numbers as you attach tags to the
components.
Directions: During the presentation, use these worksheets to take notes as the function of each
component is explained. Use the parts book and the hydraulic schematic to fill in the required
information. Place the correct letter or number from the machine next to the listed component.
Example: 20 Pilot Pump

Location: The single section gear pump mounted below the implement drive pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold and pilot systems.
Parts Manual Part Name: Pump Gp - Gear Part No.: 186-6423
Pilot Filter
Location: On the rear of the hydraulic tank at the front of the pump compartment.
Function: Filters pilot oil before pilot oil goes to any of the pilot systems.
Parts Manual Part Name: Part No.:
Pilot System Pressure Test Port

Location: Quick disconnect nipple located on the outlet side of the pilot oil filter base.
Function: For measuring the pilot system pressure.
Pilot Manifold
Location: On the inside left of the swing frame below the main control valve.
Function: A manifold block containing the travel speed solenoid, the swing brake release solenoid, the
hydraulic activation solenoid, and the hydraulic activation control valve. Distributes pilot
system oil to various systems on the machine.

Lab A Worksheet 2
Pilot System Pressure Relief Valve

Location: On the base of the pilot oil filter.
Function: Limits the pilot system pressure.
Pilot System Accumulator
Location: On the inside right of the swing frame below the main control valve.
Function: Provides stored energy to the pilot system. The pilot system accumulator dampens pressure
spikes in the pilot system during normal operation. Also, allows the operator to lower the
implements when the engine is shut down.
Swing Parking Brake Solenoid Valve

Location: The second solenoid from the top of the pilot manifold.
Function: When energized by the Engine/Pump Control Module, the solenoid sends pilot system oil to
release the swing brakes.
Hydraulic Actuation Control Valve

Location: Only valve on the Pilot Oil Manifold that is not directly controlled by a solenoid.
Function: When actuated by the Hydraulic Actuation Solenoid Valve, this control valve directs pilot oil
to the joysticks and the remainder of the pilot system to enable activation and control of the
machine's hydraulic functions.
Lab A Worksheet 3
Hydraulic Actuation Solenoid Valve

Location: On the bottom of the pilot manifold.
Function: When actuated by the Hydraulic Actuation Lever, this solenoid valve directs pilot system oil
to actuate the Hydraulic Actuation Control Valve.
Schematic Grid Location: Part No.:

Parts Manual Part Name:
Hydraulic Actuation Lever

Location: On the left operator console.
Function: Opens and closes the hydraulic actuation microswitch. When the hydraulic actuation micro
switch is closed, an electronic signal is sent to the Hydraulic Actuation Solenoid Valve.
Power Shift Solenoid Valve

Location: Below the drive pump regulator.
Function: It receives a PWM signal from the Engine/Pump Control Module, based upon engine speed,
engine speed dial position, and pump output pressures. The Power shift PRV then sends
modulated pilot system pressure to the implement pump regulators to assist in regulating
implement pump flow.
Pilot Pressure Release Line for Swing Parking Brakes

Location: The pilot pressure line going to the swing brake on the rear of the swing motor.
Function: Provides pilot system oil to the swing brake solenoid for releasing the swing brake. The
swing brakes are spring applied and released by pilot pressure.

Lab A Worksheet 4
Two Speed Travel Solenoid Valve

Location: The top solenoid valve mounted on the pilot manifold.
Function: When this solenoid valve is actuated by the Engine/Pump Control Module, pilot system
pressure is sent to the speed change valves in the travel motors. When the speed change
valves are actuated, the travel motor swashplates are set at the minimum angle for fast
travel speed.
Implement/Swing Resolver Valve

Location: On the bottom of the operator station. Located inside the second belly pan compartment
from the front of the machine, under the operator's seat.
Function: Ensures that the highest joystick signal pressure, regardless of function, is directed to the
Implement/Swing Pressure Switch.
Swing/Boom Priority Valves
Location: Located under the main control valve, behind the swing bearing, on the right hand side of
the frame for the upper structure.
Function: Allows the operator to adjust hydraulic flow priority to the swing or boom circuits,
depending SOLELY on the movement of the joysticks.
Left Travel Pressure Switch

Location: On the left side of the travel pilot control valve below the operator's station.
Function: Signals the Engine and Pump Control Module that the left travel pedal is activated.

Lab A Worksheet 5
Implement/Swing Pressure Switch

Location: On the Implement/Swing Resolver Valve.
Function: Signals the Engine and Pump Control Module that the implement or swing functions have
been activated.
Straight Travel Pressure Switch

Location: On the straight travel control valve below the operator's station.
Function: Signals the Engine and Pump Control Module that the straight travel function is activated.
Right Travel Pressure Switch

Location: On the right side of the travel control valve below the operator's station.
Function: Signals the Engine and Pump Control Module that the right travel pedal is activated.
Pilot System S•O•S Fitting

Location: On the top left side of the pilot filter base, as viewed from outside the pump compartment.
Function: Allows the technicians to obtain S•O•S. samples from the hydraulic system.

Lab B: Test and Adjust Pilot System Relief Valve
The instructor may wish to purposely misadjust the pilot system relief
valve, and then require the students to adjust the relief to a value within
specifications.

EXERCISE
Perform the pilot system relief valve adjustment procedure.
Record the specification and actual values of the pilot system relief valve.
with the students.
MATERIALS NEEDED Lab B Worksheets
A 330C Hydraulic Excavator
330C Excavator Hydraulic System Testing and Adjusting

(Form RENR5435)
1 - 8T0856 Gauge [6000 kPa (870 psi)]

Lab B Worksheet
Test and Adjust Pilot System Relief Valve
Machine Model Date
Serial Number Service Meter Hours
Tooling for Pilot Relief Valve Test
1 - 8T0856 Gauge [6000 kPa (870 psi)]
NOTE: For the complete procedures to test and adjust the pilot system relief valve, refer to the
Service Manual module "330C Excavator Hydraulic System, Testing and Adjusting"
(Form RENR5435).
Item Specification Actual

Pilot relief valve
NOTE: Test the pilot relief valve pressure with the engine speed dial at Position
10. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
Lab C: Locate and Identify Implement/Travel Pumps and

Pump Components
Lettered or numbered tags should be made up and placed on the

implement/travel pump components by the instructor. The students can
then place the correct number or letter on the blank next to the component
name on the worksheets. Refer to the handout included to help identify
the component locations on the machine.

EXERCISE
with the students.
MATERIALS NEEDED Lab C Worksheets
A 330C Hydraulic Excavator with the implement/travel pumps

and pump components tagged
Tags

SERV2723 - 10 - Instructor Module
Lab C Worksheet 1
Locate and Identify Implement/Travel Pumps and Pump Components
INSTRUCTOR NOTE: Fill in the appropriate letters or numbers as you attach the tags to the
components.

Implement/Travel Pump Group

Location: In pump compartment on center of flywheel housing/pump drive.
Function: Supplies oil to the main control valve.
Drive Pump
Location: Bottom pump in the implement pump housing driven by the engine flywheel.
Function: Supplies oil to the left half of the main control valve.
Idler Pump
Location: Top pump in the implement pump housing driven by the drive pump.
Function: Supplies oil to the right half of the main control valve.

Lab C Worksheet 2
Suction Line
Location: The single line connected to the center of the implement/travel pump.
Function: The supply line from the hydraulic tank to the main implement/travel pump.
Drive Pump Discharge Line

Location: Bottom of drive pump.
Function: Pump discharge pressure line from the drive pump to the main control valve.
Pump Case Drain Line

Location: Connected to top of the idler pump
Function: A line sending internal leakage oil from the front pump back to the hydraulic tank.
Maximum Angle Adjustment

Location: On the right end of the drive and idler pump regulators facing toward the front of the
machine.
Function: Changes the pump swashplate maximum angle stop to set maximum pump flow.
Negative Flow Control (NFC) Adjustment

Location: On the left end of the drive and idler pump regulators facing toward the rear of the
machine.
Function: Increases NFC signal pressure required to destroke pump.

Lab C Worksheet 3
Engine and Pump Control Module

Location: The top ECM in the compartment behind the cab.
Function: Controls the implement/travel pump power shift solenoid. Monitors the implement/travel
pump system pressure sensor.
Implement/Travel Pump Regulator

Location: Mounted to the end of each pump.
Function: Regulates pump output oil flow based on the signal pressures it receives.
Negative Flow Control (NFC) Signal Pressure Port

Location: On top left of the idler pump regulator. On the bottom left of drive pump regulator.
Function: Receives a flow demand signal from the main control valve.
Power Shift Signal Pressure Port

Location: On left rear of idler pump regulator. On left rear of drive pump regulator.
Function: Receives the power shift pressure signal from the power shift proportional reducing
solenoid valve.
Horsepower Control Pressure Adjustment

Location: On front of each pump regulator.
Function: Regulates the pump discharge pressure point on the constant horsepower curve where the
pump regulator begins to destroke the pump.

Lab C Worksheet 4
Implement/Travel Pump Pressure Sensors

Location: The pressure sensors on the front of the main implement pump.
Function: Signals the Engine and Pump Control Module with the pressure being produced in the
implement/travel systems.

Lab D: Test and Adjust Implement/Travel Pumps
This Lab Exercise consists of the following sections:

- Test and Adjust Constant Horsepower Controls (Flowmeter Test)
- Test and Adjust Negative Flow Controls

EXERCISE
Divide the class into groups and have each group perform one of the tests
on the excavator. Have the students record the test results on the Lab D
Worksheets.
After each group makes the adjustments, have another group check the
pressures to ensure they are within machine specifications.

with the students.
MATERIALS NEEDED Mechanic’s Tool Box and hand tools
Appropriate Service Manual modules
Lab D Worksheets

(Form RENR5435)
Refer to each Test Worksheet for the tooling required.

Lab D Worksheet 1
Test and Adjust Implement/Travel Pump Constant Horsepower Control
Machine Model Date
Constant Horsepower Control Test Tooling:
1 - 8T0856 Gauge [6000 kPa (870 psi)]

1 - 8T0861 Gauge [60000 kPa (8700 psi)]
1 - 4C9910 Portable Hydraulic Tester (flow meter)
1 - 6V9840 Swivel Tee
1 - 9U7335 Blocking Cover
1 - 1U8303 Fitting
1 - 5K9090 O-ring seal
1 - 5P0201 Hose
1 - 5P1010 Sleeve
1 - 4C8767 Coupling
1 - 7M8485 O-ring seal
1 - 4I6141 Coupling
1 - 8C9026 Adapter
1 - 6V9854 Swivel elbow
1 - 1P3703 Rectangular seal
1 - 8T4184 Bolt
1 - 8T4223 Hard washer
1 - 6V0400 Half flange
1 - 1U8292 Adapter
NOTE: For the complete procedure to test and adjust the implement/travel pump constant
horsepower control, refer to the Service Manual module "330C Excavator Hydraulic System,
Testing and Adjusting" (Form RENR5435).
Lab D Worksheet 2
Test and Adjust Implement/Travel Pump Constant Horsepower Control
330C IMPLEMENT/TRAVEL PUMP P-Q CURVE

200
150
FLOW (L/min)
100
50
5 10 15 20 25 30
PRESSURE (kPa x 1000)
PUMP FLOW TEST

Measuring Points
13700 kPa 17700 kPa 19600 kPa 25500 kPa 29400 kPa
(1975 psi) (25500 psi) (2850 psi) (3700 psi) (4250 psi)
Measured Flow liter/min Drive Pump
(US gpm) Idler Pump
Oil Temperature °C Drive Pump
(°F) Idler Pump
Drive Pump
Engine Speed (rpm)
Idler Pump
Corrected Flow L/min Drive Pump
(US gpm) Idler Pump
Spec. Flow L/min
(US gpm) Each Pump
FORMULA FOR PUMP FLOW CORRECTION

Measured Flow x 1800 rpm
Corrected Flow =
Measured rpm
Lab D Worksheet 3
Test and Adjust Implement/Travel Pump Negative Flow Control
Machine Model Date
Negative Flow Control Test Tooling:

1 - 8T0855 Gauge [4000 kPa (580 psi)] 1 - 8T4223 Hard washer
1 - 8T0861 Gauge [60000 kPa (8700 psi)] 1 - 6V0400 Half flange
1 - 4C9910 Flow meter 1 - 1U8292 Adapter
1 - 6V9840 Swivel Tee 1 - 6V9508 Plug
1 - 9U7335 Blocking Cover 1 - 8T8902 Tee
1 - 1U8303 Fitting 1 - 6V3014 Hose Assy.
1 - 5K9090 O-ring seal 1 - 6V8397 O-ring seal
1 - 5P0201 Hose 1 - 3J1907 O-ring seal
1 - 5P1010 Sleeve 1 - 6V3965 Fitting
1 - 4C8767 Coupling 1 - 6V4134 Coupler
1 - 7M8485 O-ring seal 1 - 6V3989 Fitting
1 - 4I6141 Coupling
1 - 8C9026 Adapter
1 - 6V9854 Swivel elbow
1 - 1P3703 Rectangular Seal
1 - 8T4184 Bolt
NOTE: For the complete procedure to test and adjust the implement/travel pump destroking
pressure, refer to the Service Manual module "330C Excavator Hydraulic System, Testing and
Adjusting" (Form RENR5435).
Pump Specification Actual

Drive
Idler
Lab E: Locate and Identify the Main Control Valve and

Main Control Valve Components
Lettered or numbered tags should be made up and placed on the main

control valve components by the instructor. The students can then
place the correct number or letter on the blank next to the component
name on the worksheets. Refer to the handout included to help
identify the component locations on the machine.

EXERCISE
The parts manual should be used in the classroom to locate and
identify components and their respective part numbers prior to
machine component identification.
with the students.
MATERIALS NEEDED Lab E Worksheets
Lab E Handout
A 330C Hydraulic Excavator with the main control valve and

main control valve components tagged
Tags

Lab E Worksheet 1
Locate and Identify the Main Control Valve and Main Control Valve Components
components.

Implement Control Valve

Location: Between the swing frame rails in front of the engine.
Function: Controls the boom, stick, bucket, travel and attachment functions and contains the
relief valves.
Boom I Spool
Location: B (Refer to Lab E Handout 1).
Function: Controls oil flow from the idler pump to the boom function.
Boom II Spool
Location: J (Refer to Lab E Handout 1).
Function: Controls oil flow from the drive pump to the boom function.
Lab E Worksheet 2
Bucket Spool
Location: C (Refer to Lab E Handout 1).
Function: Controls the bucket curl function.
Standard Attachment Spool (AUX Stem 1)

Location: D (Refer to Lab E Handout 1).
Function: Directs oil to an attachment circuit, if the machine is equipped.
Straight Travel Spool

Location: F (Refer to Lab E Handout 1).
Function: Directs the drive and idler pump oil flow. Allows the machine to travel in a straight line
when travel and implement functions are used simultaneously.
Stick I Spool
Location: I (Refer to Lab E Handout 1).
Function: Controls oil flow from the drive pump to the stick function.
Stick II Spool
Location: A (Refer to Lab E Handout 1).
Function: Controls oil flow from the idler pump to the stick function.
Lab E Worksheet 3
Left Travel Spool

Location: G (Refer to Lab E Handout 1).
Function: Directs oil to the left travel motor.
Right Travel Spool
Location: E (Refer to Lab E Handout 1).

Function: Directs oil to the right travel motor.
Boom Cylinder Rod End Line Relief Valve

Location: K (Refer to Lab E Handout 1).
Function: Limits the maximum pressure in the boom cylinder rod end circuit when an outside force
acts on the boom.
Bucket Load Check Valve

Location: L (Refer to Lab E Handout 1).
Function: The load check function prevents an implement from moving until pump discharge pressure
is higher than work port pressure.
Main Relief Valve

Location: P (Refer to Lab E Handout 1).
Function: Limits the oil pressure in the implement and travel circuits when the machine is under load.

Lab E Worksheet 4
Boom Regeneration Valve

Location: N (Refer to Lab E Handout 1).
Function: Used to "recycle" oil from the head end of the boom cylinders to the rod end of the cylinders
during the BOOM LOWER operation, which improves system response, controlability, and
efficiency.
Boom Drift Reduction Valve

Location: On lower front of boom spool on main control valve, just above the pilot accumulator.
Function: Prevents boom cylinders from drifting down due to leakage through the boom spool.
Stick Drift Reduction Valve

Location: On lower front of stick spool on main control valve.
Function: Prevents stick cylinder from drifting in due to leakage through the stick spool.

Location: The top and bottom ECMs in the compartment behind the cab.
Function: The top ECM controls the machine monitoring system. The bottom ECM controls the tool
functions.
Stick Regeneration Control Valve

Location: O (Refer to Lab E Handout 1).
Function: Directs oil from the rod end of the stick cylinder to the head end during the STICK IN
operation.
Lab E Worksheets 5
Swing Control Valve

Location: H (Refer to Lab E Handout 1).
Function: Controls the swing function.

Lab E Handout 1
B
A
B
P
N
MAIN CONTROL VALVE
M
A
B
J
I
H
G
F
E
D
C
B
A
A
B
K
L
Lab F: Test and Adjust Implement Line Relief Valves and

Main Relief Valve
- Test and adjust the implement line relief valves

- Test and adjust the main relief valve

EXERCISE
Divide the class into groups. Have each group test and adjust the
implement line relief valve pressure settings. After each group makes the
adjustments, have another group check the pressures to ensure they are
within machine specifications.
Have the students record the test results on the Lab F Worksheets.

(Form RENR5435)
Lab F Worksheets
Appropriate Hydraulic System Schematic (or SIS)

Lab F Worksheet 1
Test and Adjust Implement Line Relief Valves
Machine Model Date
Line Relief Valve Pressure Tooling:

1 - 8T0861 Gauge
1 - 8T0856 Gauge
NOTE: For the complete procedure to test and adjust the line relief valves, refer to the Service
Manual module "330C Excavator Hydraulic System, Testing and Adjusting" (Form RENR5435).
Function Specification Actual

Boom raise ____________________ ____________________
Boom lower ____________________ ____________________
Stick in ____________________ ____________________
Stick out ____________________ ____________________
Bucket open ____________________ ____________________
Bucket close ____________________ ____________________
Attachment, front line relief ____________________ ____________________
Attachment, rear line relief ____________________ ____________________
NOTE: Test the line relief valve pressures with the engine speed dial in Position
2. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
Lab F Worksheet 2
Test and Adjust Main Relief Valve
Machine Model Date
Main Relief Valve Pressure Tooling:

1 - 8T0861 Gauge
NOTE: For the complete procedure to test and adjust the main relief valve, refer to the Service

Main relief valve ____________________ ____________________
Lab G: Locate and Identify Travel System, Final Drive and

Swivel Components
Lettered or numbered tags should be made up and placed on the travel


EXERCISE
with the students.
MATERIALS NEEDED Lab G Worksheets
A 330C Hydraulic Excavator with the travel system, final drive

and swivel components tagged
Tags

Lab G Worksheet 1
Locate and Identify Travel System Components
components.

Left Travel Spool

Location: The inside spool in the left half of the implement control valve.
Function: Directs oil to the left travel motor.
Right Travel Spool

Location: The inside spool in the right half of the implement control valve.
Function: Directs oil to the right travel motor.
Travel Counterbalance Valves

Location: Mounted vertically on the left and right travel motors.
Function: Provide passages for pump flow to the travel motor and return flow from the travel motor to
the tank. In addition, the counterbalance valve contains a passage that releases the travel
parking brakes on each motor. The counterbalance valve creates a partial hydraulic lock
on the travel motors during stopping and overspeeding conditions.

Lab G Worksheet 2
Travel Motor
Location: Mounted on the inside of the left and right final drive housings.
Function: Converts implement/travel pump flow to rotational motion to drive the final drive.
Forward Travel Crossover Relief Valve

Location: Located on the rear top of travel counterbalance valve.
Function: Limits the maximum pressure in the travel motor circuits.
Reverse Travel Crossover Relief Valve

Location: Located on the rear bottom of travel counterbalance valve.
Function: Limits the maximum pressure in the travel motor circuits.
Travel Parking Brake

Location: Inside the final drive housings.
Function: A stack of discs and plates that prevent the final drive from turning unless the parking brake
is released. The travel parking brake is spring applied and released with travel system
pressure when the counterbalance valve is shifted.
Travel Motor Case Drain Line

Location: On the top of each travel motor.
Function: Carries the motor case drain oil (internal leakage oil) back through the swivel to the case
drain filter.

Lab G Worksheet 3
Implement/Travel Pump Pressure Sensors

Location: The pressure sensors on the front side of the main implement pumps.
Function: Signals the Engine and Pump Control Module with the pressure being produced in the
implement/travel systems.
Travel Alarm Cancel Switch

Location: On the right operator console, top left button.
Function: When activated, turns the travel alarm off.
Forward Supply Line

Location: Attached to the bottom of the counterbalance valve for the left travel motor.
Function: Supply oil to the travel motor for forward movement. Also acts as the return line for reverse
direction operation.
Reverse Supply Line

Location: Attached to the top of the counterbalance valve for the left travel motor.
Function: Acts as the return line for forward direction operation. Also, supplies oil to the travel motor
for reverse movement.

Location: The top ECM in the compartment behind the cab.
Function: Controls the pump flow, the AEC system, the two speed travel solenoid valve, and other
electronic outputs while monitoring electronic inputs such as the implement pump pressure
sensors.

Lab G Worksheet 4
Travel Alarm
Location: Located below the hydraulic tank.
Function: Alerts spectators the machine has begun to move, FORWARD or in REVERSE.
Two Speed Travel Solenoid Valve

Location: The top solenoid valve mounted on the pilot manifold.
Function: When this solenoid valve is actuated by the Engine and Pump Control Module, pilot system
pressure is sent to the displacement change valves in the travel motors. When the
displacement change valves are actuated, the travel motor swashplates are set at the
minimum angle for fast travel speed with a reduced torque.
Two Speed Travel Switch

Location: On the right operator console, top right button.
Function: When this button is actuated by the operator, an electrical signal is sent to the Engine and
Pump Control Module. The Engine and Pump Control Module then energizes or
de-energizes the two speed solenoid at the correct switching pressures.
Travel Pedals/Levers
Location: On the cab floor in front of the operator's seat.
Function: Directs pilot oil respectively to the right and left travel control spools. Allows the operator
to control the left and right track movement independent of one another or together.
Straight Travel Pressure Switch (If Equipped)

Location: On the straight travel pilot control valve below the operator's station.
Function: Signals the Engine and Pump Control Module when the straight travel pedal is pressed.

Lab G Worksheet 5
Straight Travel Pedal (if equipped)

Location: On the cab floor mounted on the right side of the footrest.
Function: Directs a common pilot signal to the right and the left travel control spools. Allows the
operator to move the machine straight forward or reverse by pressing only one pedal.
Swivel
Location: In the center of the swing frame in front of the swing drives.
Function: Provides a rotating joint for implement/travel pump oil, pilot pump oil and travel motor
case drain oil to pass through between the upper and lower structure.
Final Drives
Location: On the rear of the roller frames.
Function: Hold the travel motor and travel counterbalance valve assemblies. Reduces the travel
motor rotational speed using planetary gearsets to increase the torque.
Right Travel Pressure Switch

Location: On the right side of the travel control valve below the operator's station.
Function: Signals the Engine and Pump Control Module that the right travel pedal is activated.
Left Travel Pressure Switch

Location: On the left side of the travel control valve below the operator's station.
Function: Signals the Engine and Pump Control Module that the left travel pedal is activated.

Lab H: Test and Adjust Travel System Components
1: Test and adjust the travel crossover relief valves

2: Measure the travel motor case drain oil flow

EXERCISE
Divide the class into groups. Have each group test and adjust the travel
crossover relief valve pressure settings and the travel motors case drain
oil flow.
After each group performs the tests, have another group check the test
results to ensure they are within machine specifications.
Have the students record the test results on the Lab H Worksheet.

(Form RENR5435)
Lab H Worksheets

Lab H Worksheet 1
Test and Adjust Travel Crossover Relief Valves
Machine Model Date
Travel Crossover Relief Valve Test Tooling:

1 - 8T0861 Gauge
1 - 8T0856 Gauge
NOTE: For the complete procedure to test and adjust the travel crossover relief valves, refer to
the Service Manual module "330C Excavator Hydraulic System, Testing and Adjusting"
(Form RENR5435).

Right Forward Travel
Right Reverse Travel
Left Forward Travel
Left Reverse Travel
NOTE: Test each travel crossover relief valve pressure with the engine speed dial at
Position 10. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
Lab H Worksheet 2
Measure Travel Motor Case Drain Flow
Machine Model Date
Travel Motor Case Drain Flow Tooling:

1 - 6V9509 Face Seal Plug
1- Hose assembly to fit travel motor case drain fitting
1- Stop watch
NOTE: For the complete procedure to test the travel motor case drain flow, refer to the Service

Right Travel Motor
Left Travel Motor
NOTE: Test the travel motor case drain flow at three different motor positions and
then average the three flows. Flows are based on the Engine Speed Dial at Position
10, and the Travel Crossover Relief Valves set at 36800 ± 1470 kPa (5350 ± 215 psi).
Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
Lab I: Locate and Identify Swing System Components
Lettered or numbered tags should be made up and placed on the swing


EXERCISE
with the students.
MATERIALS NEEDED Lab I Worksheets
A 330C Hydraulic Excavator with the swing system components

tagged
Tags

Lab I Worksheet 1
Locate and Identify Swing System Components
components.

Swing Control Valve

Location: Third spool from the outside of the left main control valve.
Function: Controls the oil supply to the swing motor.
Fine Swing Solenoid (Cushion Swing Solenoid) (If Equipped)

Location: Mounted on the front of the swing motor.
Function: When energized, provides fine control of swing movement by eliminating the abrupt start
and stop during the swing operation.
Swing Parking Brake Release Line

Location: Small line from the swing brake solenoid valve connected to the swing parking brake in the
swing drive housing.
Function: Directs pilot system oil from the swing parking brake solenoid to the swing parking brake to
release the swing parking brake in the swing drive housing.

Lab I Worksheet 2
Locate and Identify Swing System Components
Slow Return Check Valve

Location: On the rear of the left side of the implement control valve.
Function: Provides back pressure in the system return lines. Acts as a makeup valve for the swing
motor to prevent cavitation in an overrun condition.
Swing Parking Brake Solenoid Valve

Location: The center solenoid on the pilot manifold.
Function: When energized by the Engine and Pump Control Module, the solenoid sends pilot system
oil to release the swing parking brake.
Swing Joystick
Location: The left joystick in the cab.
Function: Controls the pilot oil used to shift the swing control spool which in turn sends hydraulic oil
to the swing motors to swing the machine right.
Anti-reaction Valves
Location: On the bottom front of the swing motor.
Function: Help stop the swing smoothly and prevent shock loading at the end of the swing function.
Variable Swing Priority Valve

Location: On the front of the Boom II control valve on the left valve bank.
Function: Varies the amount of supply oil that is given to the swing circuit and the stick I spool
depending on the movement of the joysticks by the operator.

Lab J: Test and Adjust Swing System Components
- Test and adjust the swing system relief valves

- Test the swing motor case drain oil flow
- Test the swing brake solenoid

EXERCISE
Divide the class into groups. Have each group conduct one of the swing
system component tests on the 330C Hydraulic Excavator.
Have the students record the test results on the Lab J Worksheets.
After each group conducts a test, have another group check the test results
to ensure they are within machine specifications.

(Form RENR5435)
Lab J Worksheets

Lab J Worksheet 1
Test and Adjust Swing System Relief Valves
Machine Model Date
Swing System Relief Valve Test Tooling:
1 - 8T0861 Gauge
NOTE: For the complete procedure to test and adjust the swing system relief valves, refer to the
Service Manual module "330C Excavator Hydraulic System, Testing and Adjusting"
(Form RENR5435).

Right Swing Motor
Right Swing Relief Valve
Right Swing Motor
Left Swing Relief Valve
Left Swing Motor
Right Swing Relief Valve
Left Swing Motor
Left Swing Relief Valve
NOTE: Test each travel crossover relief valve pressure with the engine speed dial at
Position 10. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
Lab J Worksheet 2
Test Swing Motor Case Drain Flow
Machine Model Date
Swing Motor Case Drain Flow Tooling:

1-6V9830 Cap
1-6V8398 O-ring Seal
1- Container for Measuring
1- Stop watch
NOTE: For the complete procedure to test the swing motor case drain flow, refer to the Service

Right Swing Motor
Left Swing Motor
NOTE: Test the swing motor case drain flow at three different motor positions and
then average the three flows. The Engine Speed Dial should be at position "10", and
the Swing Relief Pressures set at 28900 ± 980 kPa (4190 ± 140 psi). Hydraulic oil
temperature should be 55° ± 5°C (131° ± 9°F).
Lab J Worksheet 3
Test Swing Brake Solenoid Valve
Machine Model Date
Swing Brake Solenoid Test Tooling:
1 - 8T8902 Tee (3/8 in. ORFS w/9/16 in. SAE thd. tap)
1 - 6V3965 Nipple, Valved (w/9/16 in. SAE ext. thd.)
1 - 3J1907 O-ring Seal
1 - 6V3079 Hose (14 ft. long w/1/8 in. NPTF ext. thd.)
2 - 6V4143 Coupler, Valved (w/1/8 in. NPTF int. thd.)
1 - 8T0856 Gauge [6000 kPa (870 psi)]
1 - 6V3989 Nipple, Open (w/1/4 in. NPTF int. thd.)
NOTE: For the complete procedure to test the swing brake solenoid valve, refer to the Service

Swing Brake
NOTE: Test the swing brake solenoid with the machine controls in the following
conditions: Engine Speed Dial "10", and AEC Switch "OFF." Hydraulic oil
temperature should be 55° ± 5°C (131° ± 9°F).
Lab K: Return and Cooling System Components
Lettered or numbered tags should be made up and placed on the return

and cooling system components by the instructor. The students can then
place the correct number or letter on the blank next to the component
name on the worksheets. Refer to the handout included to help identify
the component locations on the machine.

EXERCISE
with the students.
MATERIALS NEEDED Lab K Worksheets

A 330C Hydraulic Excavator with the return and cooling system
components tagged
Tags
Lab K Worksheet 1
Locate and Identify Cooling and Return Systems Components
components.

Hydraulic Cooler Bypass Valve

Location: On the rear left side of the implement control valve.
Function: When open due to a restriction in the hydraulic oil cooler, hydraulic system return oil is sent
directly to the return oil filters, bypassing the hydraulic oil cooler.
Slow Return Check Valve

Location: On the rear of the left side of the implement control valve.
Function: Provides back pressure in the swing system return lines. Also acts as a makeup valve
during a swing motor overrun, which prevents cavitation.
Hydraulic Oil Cooler

Location: At the left rear corner of the machine in front of the engine.
Function: Provides cooling for the hydraulic oil.

Lab K Worksheet 2
Locate and Identify Cooling and Return Systems Components
Radiator
Location: At the left rear corner of the machine in front of the engine.
Function: Provides cooling for the engine coolant.
Case Drain Filter

Location: Behind the hydraulic tank, next to the hydraulic return filter.
Function: Filters the case drain oil from the pumps and motors.
Hydraulic Return Oil Filter

Location: Behind the hydraulic tank.
Function: Filters all the return oil from the implements, swing and travel circuits.
Hydraulic Fan Pump

Location: Left side of engine toward the rear of the machine.
Function: Provides pump flow to the hydraulically driven cooling fan.
Fan Pump Relief Valve

Location: Mounted to the wall inside the pump compartment.
Function: Limits oil pressure in the fan hydraulic circuit.

04/02 Case Study
CASE STUDY
INSTRUCTOR NOTE The following section provides a troubleshooting case study with a
suggested troubleshooting process. You may want to work through the
case study and make your own notes. The actual student case study,
without the possible solution, is located in the Student Materials Section.
This case study is designed to promote logical troubleshooting

procedures. To do this, the students can complete the exercise in either of
the following ways:
A. Each student may complete the exercise individually and then

discuss the solution as a class.
B. Students may complete the exercise in small groups and then

discuss the solution as a class.
Summarize the results for each step using flipcharts or the blackboard.
You may want to provide the students with possible answers after the
discussion.
Students should use their class notes and other reference materials to
complete the exercise.
04/02 Case Study
"C" Series Excavator Hydraulic System Case Study
DIRECTIONS Students should use the service manual and class notes to complete the
exercise. Have the students answer the questions on the Troubleshooting
Exercise Worksheet. Discuss the exercise with the students after they
have had time to answer the exercise questions.
SITUATION The following exercise is based on a possible field complaint.
A customer is using a 330C in a tamping operation. The operator of the

excavator reported to his supervisor that the machine's boom drifts down
after four or five tamping passes. When tamping, the stick is in a vertical
position and the tamping height is 3.5 to 4.0 inches.
A dealer service technician was sent to investigate the problem.

04/02 Case Study
"C" Series Excavator Hydraulic System Troubleshooting Worksheet 1
ISOLATE PROBLEM The first step in in a troubleshooting process is to gather information

before starting any work on the machine. If possible talk to the operator.
GATHER INFORMATION
Also, check the repair history of the machine and the Caterpillar Service
Information Retrieval System (SIRS). List at least three questions you
would ask an operator to help in identifying that a problem exists?
Possible answers:
What are the exact symptoms?
When did the problem occur and under what conditions?
Is the problem intermittent?
VERIFY Verify the problem exists. Operate the machine to duplicate the problem,
preferably under similar operating conditions. Compare the operation to a
known good machine. Perform sensory checks such as looking, listening,
touching, and smelling to verify a problem exists.
PERFORM VISUAL When troubleshooting always perform a visual inspection first. Look for
INSPECTION the obvious. List at least three typical items that should be inspected
during a visual inspection. Possible answers:
Check fluid level
Check lines and connections for damage or leaks
Check control linkages for damaged or broken components
STATE PROBLEM After verifying a problem exists, state in your own words what the
problem is. Caution: Do not identify the solution. Possible answer:
The machine seems to not have enough power for digging under
normal conditions. The problem seems to affect all implements.
04/02 Case Study

LIST POSSIBLE The next step in the process is to list all of the possible causes of the
FAULTS
problem. Identify all systems and components that could be causing the
problem, including the least obvious. List at least four things that could
be checked. Possible answers:
There is an internal leakage in a/the boom cylinder(s)
There is a boom cylinder head end line leaking
The boom cylinder head end line relief is leaking
Viscosity of hydraulic oil is incorrect
The boom drift reduction valve is not working correctly
The boom I spool is not shifting properly back to neutral
DEVISE TESTS AND Now, create a list of tests that should be performed and describe what the
DETERMINING ROOT tests would determine. Prioritize the tests as to which sequence they
CAUSE
should be performed in. As a general rule, always do the easiest tests
first. Also, list diagnostic tooling required. Identify at least four tests to
perform. (NOTE: the rankings are only suggested.)
2 Check pilot pressure to the boom drift reduction valve. If pilot

pressure is present (at specification) during a boom down and
there is no residual pressure when the boom down is stopped,
then the shuttle valve that vents the dump spool is receiving the
correct signals.
Tooling needed: Pressure gage
1 Perform basic drift test on the boom. Doing this test can verify
that there is a real problem outside of specifications.
Tooling needed: Tape measure
3 Check the boom up line relief setting. If the setting is too low,
then the boom up line relief may need adjusted.
Tooling needed: Pressure gauge
04/02 Case Study
DEVISE TESTS AND 4 Exchange the boom up and the boom down line reliefs. This
DETERMINING ROOT will determine if the boom up line relief is defective.
CAUSE
(CONTINUED) Tooling needed: Wrenches
REPAIR FAULT After isolating the component, which you suspect from your test results is
causing the problem, either adjust or replace the component.
Circle the best response:

If during your tests you discovered that there was residual pilot pressure
to the boom drift reduction valve when the boom joystick was in the hold
position. Which one of the following components would you inspect?
1. Boom joystick
2. Boom drift reduction valve
3. Boom I spool
4. Boom cylinder rod end line relief
If during your tests you discovered that the boom cylinder head end line
relief was relieving at a pressure below specification what would be the
next step to take.
1. Adjust the boom cylinder head end line relief
2. Replace the boom cylinder head end line relief
3. Replace the boom drift reduction valve
4. Inspect the boom II spool
If the boom cylinder head end line relief valve has been adjusted, and
switching the boom cylinder head end line relief and the boom cylinder
rod end line relief stops the downward drift, what would be the next step
to take.
1. Adjust the boom cylinder head end line relief
2. Replace the boom cylinder head end line relief
3. Replace the boom drift reduction valve
4. Inspect the boom II spool
04/02 Case Study
"C" Series Excavator Electronic Control System Troubleshooting Worksheet 5
VERIFY REPAIR After completing the repair, always verify the machine is operating
correctly. List at least three things you would do to make sure the repair
was done correctly.
1. Recheck all pressures after adjustments or component replacement.
2. Recheck cycle times.
3. Operate the machine under the same conditions that produced the
problem.
4. Recheck the boom cylinder drift.
5.
Complete the service report after finishing the job.

04/02 Posttest
330C Excavator Hydraulic Systems Operation Posttest
INSTRUCTOR NOTE Classroom Posttest:
Students may refer to their course material and class notes when taking
the posttest.
Students may not consult with others during the posttest.
INDIVIDUAL EXERCISE Procedure:

Explain to the class how to fill out the posttest.
After the completion of this exercise discuss the completed post test with
the students.
MATERIALS NEEDED ____ 330C Excavator Hydraulic Systems Operation Posttest

04/02 Posttest
330C EXCAVATOR HYDRAULIC SYSTEMS OPERATION POSTTEST

ANSWERS
Directions: Modified True/False. If a question is false, underline or circle the word or words that make
the statement incorrect and replace with word(s) to make the statement correct.
Example: F 1. This is an engine class. a hydraulic system
T 1. When investigating a power complaint, first determine if the complaint is hydraulic or

engine related.
F 2. When the implement or travel controls are in use, the implement or travel pressure is
regulated by the NFC relief valve. main
T 3. The engine and pump control module receives an electrical signal from the drive pump
pressure sensor during the swing function.
T 4. The travel system pressure can be checked while stalling an implement function.
T 5. When power shift pressure to the implement pump regulators increases, the pumps
destroke.
T 6. The variable swing priority valve is controlled by the swing priority pressure reducing
valve.
F 7. Boom pilot pressure controls the swing priority pressure reducing valve. swing
F 8. The Stick II, Stick In pilot signal is controlled by the boom down pilot signal going to the
boom priority pressure reducing valve. up
T 9. The NFC relief valve system ensures the implement pumps upstroke or destroke
depending on control valve spool movement.
F 10. The maximum pressure during level travel is regulated by the travel crossover relief valve.
main
F 11. Power shift signal pressure is controlled by the monitor. engine and pump control
F 12. The power shift PRV pressure oil comes directly from the pilot manifold. filter
T 13. The implement pumps upstroke when the power shift solenoid receives a decrease in
electrical signal from the engine and pump control module.
04/02 Posttest
F 14. The Engine and Pump Control Module regulates NFC pressure to the implement pumps to
keep the engine from stalling. power shift
T 15. The horsepower adjustments on the implement pump regulators control the destroking of
the pump.
F 16. The Boom I and Boom II control valves move at the same time when Boom Up function is
activated. different times
T 17. It is possible to have the stick re-generation not function during a Stick In operation.
F 18. When the implement pumps are at standby, the NFC signal pressure is lowest. highest
F 19. The stick unloading valve is shifted during stick in operation by the Stick In pilot pressure.
rod end
T 20. The implement pump flow is controlled by three different signal pressures sent to the
pump regulators.
T 21. One of the signal pressures that control pump flow is the negative flow control pressure.
T 22. When multiple controls are activated, the highest system pressure from the right or left
half of the implement control valve is regulated by the main relief valve.
F 23. Power shift pressure can only be calibrated using the Service Tool and ET software. or
monitor panel
T 24. Diagnostic information is available from the monitor panel or by using ET.
04/02 Posttest
Directions: Fill In The Blank. Reference material and class notes may be used to determine the
correct answers.
1. The travel crossover relief valves are adjusted to what pressure? 36800 kPa (5350 psi)
2. What constant power shift pressure is set during P-Q testing? 2400 kPa (350 psi)
3. The boom head end and stick rod end line relief valves are adjusted to what pressure?
36800 kPa (5350 psi)
4. The remaining implement line relief valves are adjusted to what pressure? 36800 kPa (5350 psi)
5. The main relief valve is adjusted to what pressure for implement functions? 34300 kPa (4950 psi)
6. The swing motor left and right relief valve pressure setting is adjusted to what pressure?
26000 kPa (3750 psi)
7. The travel motor crossover relief valve pressure setting is adjusted to what pressure?
36800 kPa (5350 psi)
8. The pilot system pressure is adjusted to what pressure? 4100 kPa (595 psi)
9. The power shift pressure is adjusted to what pressures during the calibration procedure?
500 kPa (70 psi) and 2500 kPa (362 psi)
10. The travel and swing parking brakes require what pressure to release? 3030 kPa (440 psi)
11. The stick unloading valve requires what rod end return pressure to shift? 10390 kPa (1510 psi)
04/02 Posttest
Directions: Match the component with the correct function by placing the letter next to the component.
E Pilot Pump A. Provides priority oil flow to the Boom Up and
Swing operations during multiple implement
I Power Shift Pressure Solenoid operations.
B. Control signals from the left and right sections of
A Boom and Swing Priority Pressure the implement control valve.
Reducing Valves
C. Receives signals from pressure switches and
sensors. Sends a PWM signal to the power shift
N Implement/Swing Pressure Switch solenoid.
J Boom Drift Reduction Valve D. When activated, sends right pump flow to both
travel motors and left pump flow to the implement
and swing functions.
G Swing Anti-reaction Valves
E. Driven by the implement drive pump. Provides
M Hydraulic Actuation Valve pilot oil flow to the pilot oil system.
F. Provides an average pressure signal to the
O Slow Return Check Valve implement pump regulators based upon the output
of the left implement pump and the right implement
K Swing Brake Solenoid Valve pump.
G. Reduces wag during swing operations.
H Hydraulic Actuation Lever Switch
H. If this switch is closed, the Hydraulic Actuation
L Travel Pressure Switches Solenoid Valve is energized.
I. Controlled by the Engine and Pump Controller.
B Negative Flow Control Signals Provides a signal to the implement pump regulators
to control pump output under load.
D Straight Travel Valve
J. Prevents the boom cylinders from drifting down
under load.
C Engine and Pump Control
K. Receives a signal from the Engine and Pump
F Cross Sensing Signal Control Module and sends pilot system oil to
release the swing brake.
P Stick Unloading Valve L. Signals the Engine and Pump Control Module when
left or right travel is actuated.
M. Controlled by the Hydraulic Actuation Solenoid on
the pilot manifold. When activated, provides pilot
oil to the pilot oil system.
N. Signals the Engine and Pump Controller when an
implement or swing operation is activated.
O. Provides a back pressure in the return oil lines.
P. After Stick In return pressure becomes excessive
this valve shifts, opening another return oil passage
for Stick In return oil.

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Service Training

Instructor Module SERV2723

TECHNICAL INSTRUCTION MODULE

330C HYDRAULIC EXCAVATOR

MODULE LESSON PLAN

REFERENCES Service Manual Modules Form No.

REFERENCES Parts Manual

SUPPLEMENTAL Video Tape

Service Training Meeting Guides

STMG 697 "300 B Series Hydraulic Excavator, Hydraulic

Technical Instruction Modules

"300C Hydraulic Excavators, Electronic Control Systems" SERV2693

Programmed Instruction Course "Basic Electricity" SEBV0534

Student Materials (theirs to keep)

Instructor and Student Reference Materials - at least one copy of the

PREPARATION CHECKLIST (continued)

PREPARATION CHECKLIST (continued)

Prior to delivering the lab exercises perform the following steps:

Review the Laboratory Exercises section.

Prepare a machine for the class.

Gather the following special tools and fittings:

PREPARATION CHECKLIST (continued)

Gather the following special tools and fittings (continued):

PREPARATION CHECKLIST (continued)

1 - 320C, 322C, 325C or 330C Hydraulic Excavator

If a participant does not accomplish 90% or better, identify the area of

PREREQUISITE These prerequisite courses should be completed prior to participating in

• Pilot System Visual Presentation: Pilot System and Components 30 min

Lab B: Test and Adjust Pilot System Relief Valve 10 min

• Pump System Visual Presentation: Implement/Travel Pumps

Lab C: Locate and Identify Implement/Travel Pumps

Lab D: Test and Adjust Implement/Travel Pumps:

• Main Control Valve Visual Presentation: Main Control Valve and

MODULE LESSON PLAN (continued)

Lab E: Locate and Identify Main Control Valve and

Lab G: Locate and Identify Travel System, Final Drives

Lab H: Test and Adjust Travel System

• Swing System Visual Presentation: Swing System and Components 60 min

Lab I: Locate and Identify Swing System Components 30 min

MODULE LESSON PLAN (continued)

Lab J: Test and Adjust Swing System

• Return System Visual Presentation: Cooling and Return Systems

Lab K: Locate and Identify Cooling and Return Systems

• Case Study Case Study 60 min

• Posttest Posttest 30 min

• Review Review Posttest, Question and Answer Period 30 min

Total Estimated Time 19 hours

After completion of this module, the student will be able to:

2. Given a machine and the appropriate service literature perform the

3. Given all reference material and class notes:

MODULE OBJECTIVES (continued)

4. Given all reference material and class notes, on a posttest:

Cross Reference for Service Manual Pages and Visuals

Implement/Travel Pumps and

Main Control Valve, Pressure

Boom, Stick and Bucket Components 63 - 91 64 - 90

Travel System, Final Drive and

Swing System and Components 122 - 151 121 - 147

Return System and Components 151 - 157 148 - 159

Review and perform the labs before delivering this module.

Lab A: Locate and Identify Pilot System Components

INSTRUCTOR NOTE Shop Lab Exercise:

Lettered or numbered tags should be made up and placed on the pilot