Testing and Adjusting

Testing and Adjusting
365C Excavator Hydraulic System

Media Number -RENR7305-04 Publication Date -01/04/2006 Date Updated -25/04/2006
i01377146
Hydraulic System Pressure - Release

SMCS - 4250-553-PX; 5050-553-PX
The release of hydraulic pressure in a hydraulic circuit is required before service is

performed to that hydraulic circuit. Release the pressure in the following hydraulic
circuits before any hydraulic lines are disconnected or removed from that hydraulic
circuit.
 Boom hydraulic circuit

 Stick hydraulic circuit
 Bucket hydraulic circuit
 Swing hydraulic circuit
 Travel hydraulic circuit
 Attachment hydraulic circuits (if equipped)
 Pilot hydraulic circuit
 Return hydraulic circuit
Note: Refer to the Disassembly and Assembly Manual for additional information
concerning service of the components of specific hydraulic circuits.
Release Of Hydraulic Pressure From A Single

Hydraulic Circuit
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to the ground, and the
oil is cool before removing any components or lines. Remove the oil filler
cap only when the engine is stopped, and the filler cap is cool enough to
touch with your bare hand.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Perform the following Steps in order to release the hydraulic pressure from a single
hydraulic circuit of the main hydraulic system.
1. Position the machine on level ground.
g00666865
Illustration 1
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the
bucket is parallel to the ground. Lower the boom until the bucket is flat on the
ground. Refer to Illustration 1.
3. Shut off the engine.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service
to the FULL STROKE positions. This will release the high pressure only in that
single hydraulic circuit. This will also release any pressure that might be present
in the pilot hydraulic circuit.
Note: If the desired hydraulic circuit that requires service requires the activation
of a switch for operation, activate the necessary switches for the operation of the
hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.

8. Turn the engine start switch to the OFF position.
9. Slowly loosen the filler plug on the hydraulic tank and release the pressure from
the hydraulic tank. Leave the filler plug loose for a minimum of 45 seconds. This
will release the pressure that may be present in the return hydraulic circuit.
10. Tighten the filler plug on the hydraulic tank to the specified torque.
11. The pressure in the single hydraulic circuit that requires service is now released
and lines and components can be disconnected or removed from that hydraulic
circuit.
Note: If a hydraulic line for the boom, the stick or the bucket must be disconnected,
utilize the purge screws. Refer to "Purge Screws (Boom, Stick and/or Bucket Hydraulic
Circuits)".
Release Of Hydraulic Pressure From Multiple

Hydraulic Circuits
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to the ground, and the
oil is cool before removing any components or lines. Remove the oil filler
cap only when the engine is stopped, and the filler cap is cool enough to
touch with your bare hand.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop

Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Perform the following Steps in order to release the hydraulic pressure from multiple
hydraulic circuits of the main hydraulic system.
g00666865
Illustration 2
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the
bucket is parallel to the ground. Lower the boom until the bucket is flat on the
ground. Refer to Illustration 2.
4. Turn the engine start switch to the ON position without starting the engine.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service
to the FULL STROKE positions. This will release the high pressure only in that
hydraulic circuit. This will also release any pressure that might be present in the
pilot hydraulic circuit.
Note: If the hydraulic circuit that requires service requires the activation of a
switch for operation, activate the necessary switches for the operation of the
hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Start the engine.
9. Place the hydraulic activation control lever in the UNLOCKED position. Do not
move any joysticks or pedals from the NEUTRAL position during this step.
Do not activate any switches during this Step.
10. Return the hydraulic activation control lever to the LOCKED position.

12. Repeat Steps 4 through 11 for each additional hydraulic circuit that requires
service.
13. After releasing the hydraulic pressure in each of the desired hydraulic circuits,
place the hydraulic activation control lever in the LOCKED position.
14. Turn the engine start switch to the OFF position.
15. Slowly loosen the filler plug on the hydraulic tank and release the pressure. Leave
the filler plug loose for a minimum of 45 seconds. This will release the pressure
that may be present in the return hydraulic circuit.
16. Tighten the filler plug on the hydraulic tank to the specified torque.
17. The pressure in the multiple hydraulic circuits that require service is now released
and lines and components can be disconnected or removed from those hydraulic
circuits.
Note: If a hydraulic line for the boom, the stick or the bucket must be disconnected,
utilize the purge screws. Refer to "Purge Screws (Boom, Stick and/or Bucket Hydraulic
Circuits)".
Purge Screws (Boom, Stick and/or Bucket Hydraulic

Circuits)
If a hydraulic line for the boom, the stick or the bucket must be disconnected, utilize the
purge screws.
Hydraulic oil pressure can remain in the hydraulic system after the pilot
pressure is released. Serious injury can result if this remaining pressure
is not released before any service is done on the hydraulic system.
Make sure that the remaining pressure has been released by utilizing the
purge screws that are located on the boom, stick and bucket lines. Before
any purge screw is turned, the bucket and or all of the attachments must
be lowered to the ground or properly supported.
1. Locate a section of hose that will tightly fit over one of the purge screws.
g00583861
Illustration 3
(1) Hose clamp
(2) hose
2. If a section of hose cannot be located, loosen clamp (1) and disconnect hose (2)
from the radiator.
g00582501
Illustration 4
(2) Hose
(3) Purge screws (one on each line)
(A) Line for the stick
(B) Line for the bucket
(C) Line for the bucket
(D) Line for the stick

3. Connect one end of drain hose (2) to purge screw (3). Insert the other end of drain
hose (2) into an empty container.
4. Loosen purge screw (3) by 1/2 turn. Hydraulic oil will be drained from the drain
hose to the container.
Note: Dispose of drained fluid according to local regulations.
5. Tighten purge screw (3) to a torque of 13 ± 2 N·m (9.6 ± 1.5 lb ft) after all of the
hydraulic oil has been drained from the line.
g00582502
Illustration 5
(4) Purge screws for the boom

Note: Purge screws (4) for the boom are located on the boom cylinder lines. The
above procedure should be used to drain the hydraulic oil from the boom lines as
well.
6. After the hydraulic oil is drained, tighten the purge screw. Then disconnect hose
(2) from the purge screw on the hydraulic line that is being drained.
7. If the hose from the radiator was used, replace the hose with a new hose. Connect
the new hose (2) and tighten clamp (1) .
8. Pressure in the hydraulic system should now be released and lines and
components can be removed.

i02277059
Specifications
SMCS - 5050
Note: A New specification is the performance that can be expected for a new machine. A
Rebuild specification is the performance that can be expected after rebuilding the
components of a system. Performance beyond Service Limit specifications is an
indication of these problems: improper adjustment, wear, damage of relief valves and
damage of pumps.
g00872467
Illustration 1
Relief valve locations
(1) Cab
(2) Right swing motor
(3) Left swing motor
(4) Main control valve
(5) Pilot manifold
(6) Travel motor (right)
(7) Travel motor (left)

(A) Bucket cylinder line (head end)
(B) Boom cylinder line (head end)
(C) Stick cylinder line (head end)
(G) Signal relief valve (heavy lift and travel)
(H) Signal relief valve (boom and stick)
(I) Bucket cylinder line (rod end)
(J) Boom cylinder line (rod end)
(K) Stick cylinder line (rod end)
(L) Right swing motor (right relief valve)
(M) Right swing motor (left relief valve)
(N) Left swing motor (right relief valve)
(O) Left swing motor (left relief valve)
(P) Margin pressure adjustment screw (rear pump)
(Q) Margin pressure adjustment screw (front pump)
(R) Pilot relief valve
(S) Right travel crossover relief valve for forward travel (upper valve)
(T) Right travel crossover relief valve for reverse travel (lower valve)
(U) Left travel crossover relief valve for reverse travel (lower valve)
(V) Left travel crossover relief valve for forward travel (upper valve)
(W) Differential relief valve (rear pump)
(X) Differential relief valve (front pump)
(Y) Control valve for counterweight cylinder

Table 1
Relief Valve Specifications

Service Limit Torque For
New Rebuild
Locknut
30000 to
(G) Signal relief valve 32000 ± 500 32000 ± 500
32500 kPa
(boom and stick ) kPa (4650 ± kPa (4650 ±
(4350 to 4715
75 psi) 75 psi)
psi) 60 ± 10 N·m
(45 ± 8 lb ft)
(H) Signal relief valve 33000 to
35000 ± 500 35000 ± 500
(heavy lift and travel) 35500 kPa
kPa (5075 ± kPa (5075 ±
(4790 to 5150
75 psi) 75 psi)
psi)
(P) Margin pressure

adjustment screw (rear
pump) 1960 ± 50 1960 ± 50 kPa 1960 ± 50 kPa 28 ± 7 N·m
(Q) Margin pressure kPa (285 ± 7 (285 ± 7 psi) (285 ± 7 psi) (21 ± 5 lb ft)
adjustment screw psi)
(front pump)
(B) Boom cylinder line

(head end) 35000 to
37000 ± 500 37000 ± 500
37500 kPa
(C) Stick cylinder line kPa (5350 ± kPa (5350 ±
(5075 to 5440
(rod end) 75 psi) 75 psi)
psi)
(J) Boom cylinder line

(rod end) 33 ± 5 N·m
(25 ± 4 lb ft)
(K) Stick cylinder line
(head end) 32000 to
34000 ± 500 34000 ± 500
34500 kPa
(A) Bucket cylinder kPa (4900 ± kPa (4900 ±
(4650 to 5000
line (head end) 75 psi) 75 psi)
psi)
(I) Bucket cylinder line
(rod end)
(L) Right swing motor

(right relief valve) 28950 ± 500 28950 ± 500 26950 to 155 ± 29 N·m
kPa (4200 ± kPa (4200 ± 29450 kPa (115 ± 22 lb
(M) Right swing motor 75 psi) 75 psi) ft)
(left relief valve)
(N) Left swing motor
(right relief valve)
(O) Left swing motor (3910 to 4270

(left relief valve) psi)
(V) Left travel

crossover relief valve
(forward)
(U) Left travel

(reverse) 39250 ± 36250 to
39250 ± 1500 155 ± 29 N·m
1500 kPa 40750 kPa
(S) Right travel kPa (5700 ± (115 ± 22 lb
(5700 ± 220 (5260 to 5910
crossover relief valve 220 psi) ft)
psi) psi)
(forward)
(T) Right travel

(reverse)
4120 ± 100 4120 ± 100 4120 ± 100 16 ± 1 N·m

(R) Pilot relief valve
kPa (600 ± kPa (600 ± 15 kPa (600 ± 15 (12 ± 1 lb ft)
15 psi) psi) psi)
(W) Differential relief

valve (rear pump) 3000 ± 50 Differential relief valves should not be
(X) Differential relief kPa (435 ± 7 serviced.
valve (front pump) psi)
(Y) Counterweight 20600 ± 500 20600 ± 500 20600 ± 500 30 ± 2 N·m

cylinder kPa (2990 ± kPa (2990 ± kPa (2990 ± (22 ± 1 lb ft)
75 psi) 75 psi) 75 psi)
37000 ± 350 80 ± 10 N·m

Drift reduction valve N/A N/A
kPa (5350 ± (59 ± 7 lb ft)
50 psi)
Table 2
Required Tools
Part Number Description Qty

- Laptop Computer 1
JERD2129 Data Subscription for All Engines and Machines 1
139-4166 Data Link Cable As 1
7X-1701 Communication Adapter As

or or 1
171-4401 Communication Adapter As
7X-1425 Data Link Cable As (RS232) 1
4C-6500 Digital Thermometer 1
1U-5796 Pressure Differential Tool Gp 1
9U-7400 Multitach Tool Gp 1
Note: Use the Caterpillar Electronic Technician (Cat ET) or a Multitach in order to
monitor engine speed.
Table 3
Pressure change With One Turn Of Adjustment

Relief Valves
Screw
Implement
Signal relief valves 10600 kPa (1535 psi)
Travel
7050 kPa (1025 psi)
Line relief valve

6850 kPa (1000 psi)
Swing relief valve

10000 kPa (1450 psi)
Travel crossover relief valve

10000 kPa (1450 psi)
Pilot relief valve

690 kPa (100 psi)
Note: Pressure values in Table 3 are approximate values. Use a pressure gauge for
adjustment.
Preparation for Relief Valve Adjustment

2. Stop the engine.
3. Release the pressure in the hydraulic system. Refer to Testing and Adjusting,
"Hydraulic System Pressure - Release".
g00587781
Illustration 2
Pump compartment
(1) Pressure tap (power shift pressure)

4. Connect a 4000 kPa (580 psi) pressure gauge to pressure tap (1) .
Illustration 3 g01140225
Pump compartment (rear view)
(2) Pressure tap (front pump delivery pressure)
(3) Pressure tap (rear pump delivery pressure)

5. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (2). Connect a
60000 kPa (8700 psi) pressure gauge to pressure tap (3) .
g01117935
Illustration 4
(55) Service connector

6. Connect Cat ET to service connector (55) .
7. Start the engine.

g01117636
Illustration 5
Monitor and keypad
(50) Engine speed
(51) Gain/Response
(52) AEC switch
(53) Gain/Response switch
(54) Heavy lift switch

8. Place the machine controls at the following settings:
o Engine speed dial "10"
o AEC switch OFF
o Heavy lift switch OFF (digging mode)
o Gain/Response "CAT" (normal mode)
Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm
settings.
10. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
Note: Normal operations of the engine and pumps are necessary for the pressure
adjustments. If the results of the pressure adjustment are not correct, then the engine and
the pump characteristic curve needs to be checked. Slow output flow from the pump is an
indication of air in the hydraulic system. Make sure that no air is present in the hydraulic
system. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

i02207371
Specifications - Boom and Stick Lowering Control
Valve
SMCS - 5050
g00749029
Illustration 1
Relief valve locations
(1) Main control valve
(A) Relief valve (stick lowering)
(B) Relief valve (boom lowering)
(C) Counterweight relief valve

g00714317
Illustration 2
Section A-A
(D) Hammer relief valve
(E) Line relief valve

Table 1
Specifications
Relief Valve New Torque For Locknut
(A) Relief valve (stick lowering)

37000 kPa (5350 psi) 33 ± 5 N·m (25 ± 4 lb ft)
(B) Relief valve (boom lowering)

37000 kPa (5350 psi) 33 ± 5 N·m (25 ± 4 lb ft)
(C) Counterweight relief valve

20600 kPa (2990 psi) 30 ± 2 N·m (22 ± 1 lb ft)
(D) Hammer relief valve
16000 kPa (2320 psi) 33 ± 5 N·m (25 ± 4 lb ft)
(E) Line relief valve

37000 kPa (5350 psi) 33 ± 5 N·m (25 ± 4 lb ft)
Table 2
Required Tools
Part Number Description Qty
- Laptop Computer 1
JERD2129 Data Subscription for All Engines and Machines 1
139-4166 Data Link Cable As 1
7X-1701 Communication Adapter As

or or 1
171-4401 Communication Adapter As
7X-1425 Data Link Cable As (RS232) 1
8T-0470 Thermistor Thermometer 1
9U-7400 Multitach Tool Gp 1
Note: Use the Caterpillar Electronic Technician (Cat ET) or a Multitach in order to
monitor the engine speed.
Previous Screen
Product: EXCAVATOR
Model: 375 L EXCAVATOR 9WL
Configuration: NO EQUIPMENT SELECTED

375 & 375L EXCAVATORS HYDRAULIC SYSTEMS
Media Number -SENR6033-02 Publication Date -08/12/1995 Date Updated -12/10/2001
Testing And Adjusting

Introduction
NOTE: This manual is divided into the following two main sections:
1. Checking Procedures
2. Testing And Adjusting
NOTE: As a general rule, if there is doubt as to the cause of a problem, the electronic
system should be checked first.
NOTE: The material in this module is intended to be used with the separate module,
"Electrical Schematic", Form No. SENR6015.
Reference: For information on Systems Operation of the above, make reference to:
Systems Operation, Starting and Charging System SENR8735, Engine and Pump
Electronic Control System SENR6155 and/or Systems Operation Hydraulic System
SENR6024 or SENR8953.
This manual contains information on the troubleshooting procedures of the in the 375 and
375 L excavators. For troubleshooting the engine components, refer to the module
Systems Operation, Testing And Adjusting for CAT 3406 ATAAC Diesel Engine, Form
No. REGO1438.
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" sectio in this
module.
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)
(Hyd #1)
Hydraulic Oil Supply
Reference: Refer to Operation And Maintenance, Form No. SEBU6542.
(Hyd #2)
Suction Filter Clean Up
Reference: Refer to Operation And Maintenance, Form No. SEBU6542.
(Hyd #4)
Pilot Pressure Check At Main Control Valve Inlet
Main Control Valve Compartment (Typical Example)

(1) Pilot line (bucket close). (2) Pilot line (stick in). (3) Pilot line (boom raise). (4) Pilot line (reverse left
travel). (5) Pilot line (reverse right travel). (6) Main control valves.
Main Control Valve (Viewed From Rear)

(7) Pilot line (forward right travel). (8) Pilot line (forward left travel). (9) Pilot line (boom lower). (10) Pilot
line (stick out). (11) Pilot line (bucket open).
To check the pilot oil pressure at the inlet of each valve of the main control valves,
connect a tee between each pilot line and its control valve.
Attach a 4900 kPa (700 psi) pressure gauge to the tee.
(Hyd #5)
Pilot Oil Pressure Check At Swing Control Valve Inlet
In Front Of Main Control Valves

(12) Pilot line (left swing). (13) Swing control valve. (14) Pilot line (right swing).
Connect a tee between pilot lines (12) and (13) and the swing control valve.
Attach a 4900 kPa (700 psi) pressure gauge to the tee.
(Hyd #6)
Swing Motor Performance Problem
To check the swing motor performance, measure the amount of swing motor case drain
oil.
Swing Motor
(15) Drain hose.
1. Disconnect drain hose (15) from the tee on the swivel.
2. Install a cap in the opening of the tee.
3. Put the open end of the drain hose into a suitable measuring container.
4. With the swing lock pin in the LOCKED position, operate the swing control for one
minute.
5. Measure the amount of swing motor case drain oil.
NOTE: The maximum acceptable case drain oil with a swing relief pressure setting of 27
500 +490 -980 kPa (4500 +72 - 140 psi) must be:
For a New swing motor ... 30 liter/min (7.9 U.S. gpm)
For a Rebuilt swing motor ... 34.5 liter/min (9.1 U.S. gpm)
(Hyd #7)
Travel Motor Performance Problem
To check the travel motor performance, measure the amount of case drain oil.
Travel Motor (Left Track)
(17) Connector. (18) Drain hose.
To measure case drain oil, do the following:
1. Disconnect drain hose (18) from connector (17).
2. Connect a hose to connector (17).
3. Put the other end of the hose into a measuring container.
4. With the track blocked, operate the travel control for one minute.
5. Measure the amount of case drain.
NOTE: The maximum acceptable case drain with a main relief pressure of 34 300 ± 490
kPa (5000 ± 72 psi) must be:
For a NEW travel motor ... 30 liter/min (7.9 U.S. gpm)
For a REBUILT travel motor ... 34.5 liter/min (9.1 U.S. gpm)
Introduction
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.
Swing lock must be engaged before service is started.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
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.
Each of the implement circuits has a load check valve to prevent cylinder drift during
spool movement. Each circuit also has makeup valves for flow of oil to both ends of the
cylinders and motors and there is a line relief valve for each of the cylinder and swing
motor circuits.
Visual checks and measurements are the first steps when troubleshooting a possible
problem. Next, do the Checks During Operation, and last, do the required checks and
adjustments on the machine.
Use a stopwatch, a magnet and a mm (inch) ruler for the following basic checks.
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 oil level in the hydraulic tank. Slowly loosen the hydraulic tank air vent plug
and release the pressure before the filler cap 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 the pumps.
Operational Tests
NOTE: For specifications given in Operational Tests, a NEW specification is the
performance that can be expected of 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 are for a machine equipped with 8800 mm (28 ft 10 in)
boom, 4400 mm (14 ft 5 in) stick and SAE 2.8 m3 (3-5/8 yd3) bucket.
NOTE: The power mode selector switch must be placed at Mode III position, unless
otherwise specified, during tests.
Operational Test Preparations
Conditions for the following tests are as follows:

1. Engine speed: No load high idle, 1860 ± 50 rpm
2. Hydraulic oil temperature: 55 ± 5°C (130 ± 9°F)
NOTE: Fully move the stick in and out several times until the normal hydraulic
oil temperature is reached.
3. Delivery pressure settings:
For implements ... 31 400 ± 490 kPa (4550 ± 72 psi)
For travel ... 34 300 ± 490 kPa (5000 ± 72 psi)
4. Travel crossover relief valve pressure setting:
For travel test ... 36 300 ± 980 kPa (5250 ± 140 psi)
5. Swing relief valve pressure setting:
For swing test ... 27 500 ± 490 kPa (4000 ± 72 psi)
6. Line relief valve pressure setting:
For cylinder test ... 33 300 ± 980 kPa (4850 ± 140 psi)
7. Margin pressure setting:
1960 ± 100 kPa (285 ± 14 psi)
Travel On Level Ground

Test Preparation:
1. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft)
long.
2. Draw a 25 m (82.5 ft) straight line on the travel test ground as a reference line.
3. Position one track in line (parallel) with the reference line. Put the machine in the
travel test position as shown in the illustration.
4. 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 deviation from the reference line.
4. Repeat the above procedure with the travel speed switch in the 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 travel deviation from the reference line:
Travel On Level Ground (Optional Test)

NOTE: If suitable ground (as stated in Step No. 1 in "Test Conditions" for Travel Test on
Level Ground) cannot be found, the following test should be done as a substitute:
Test Preparation:
1. Place the machine on level ground.

Test Procedure:
1. Raise a track for the test as shown in the illustration.
2. Put a mark on a shoe of the raised track.
3. Run the raised track with the engine speed dial at high idle (position "10") and the
travel speed switch in HIGH (rabbit sign).
4. Measure the time required for the track to make three complete turns (revolutions) in
each direction (FORWARD and REVERSE).
5. Repeat the above procedure with the travel speed switch in LOW (turtle sign) position.
Drift On A Slope
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:
1. Place the machine on a slope of 12°. The slope surface must be hard and smooth.
2. Put the implements in the position as 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 slope.
2. Stop the engine and time three minutes (using a stopwatch).
3. Measure the distance the tracks have moved on the slope.
Swing Speed And Over Swing (On Level Ground)
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. Place the machine on level ground as shown in the illustration.
2. Put marks on both inner and outer races of the swing bearing to indicate relation of two
positions.
3. 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 until the machine completes a
360° swing operation. Return the swing control lever to the NEUTRAL position at the
end of the 360° 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 360° rotation.
Test Procedure (Speed):
1. Move the swing control lever to the LEFT or RIGHT and measure the time it takes to
complete a 180° swing operation.
Swing Speed And Drift (On A Slope)
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.

2. Put the implements to maximum reach and fill the bucket with soil. The bucket should
be positioned above the ground to clear any obstructions.
Test Procedure (Speed):
1. Put positional marks on the inner and outer races of the swing bearing. Place the upper
structure at a 90° angle to the tracks.
2. Measure the time needed to swing the upper structure 90° counterclockwise up hill. Do
the same for a 90° turn clockwise up hill.
Test Procedure (Drift):
1. Stop the machine on a 12° slope. Place the upper structure at a 90° angle to the lower
structure as shown in the illustration.
2. Put marks on inner and outer races of the swing bearing.

3. Stop the engine.
4. Leave the machine in this position for three minutes, and measure swing drift on the
circumference of the swing bearing.
5. Rotate the upper structure 180° from the original position as described in Step 1.
6. Repeat Steps 2 through 4.
Cylinder Drift
Test Preparation:
1. Place the machine on level ground as shown in the illustration. Set engine speed and
increase the hydraulic oil to normal operating temperature.
2. 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. 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):
1. Fully extend the bucket cylinder.
2. Raise the boom high enough until the stick is perpendicular to the ground and stop the
engine.
3. Measure the bucket cylinder's length from pin to pin.
4. Stop the engine.
5. Leave the machine in this position for three minutes the measure the bucket cylinder's
length from pin to pin for drift.
Cylinder Operating Speed
Test Preparation:
1. Place the machine on level ground.
2. The bucket must be empty.
Test Procedures (Boom Cylinders):
1. Fully retract the bucket and stick cylinders.
Extension Test;
Measure the time required for the boom cylinders to reach full extension position starting
with the bucket on ground.
Retraction Test;
Measure the time required for the bucket to come in contact with the ground from the full
extension position of 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.
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.
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 (boom, stick, and bucket) before
any hydraulic lines or components are disconnected or removed.
1. Fully retract the rod in the stick cylinder.
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, bucket, stick, and swing full strokes. This will
relieve 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 air vent plug back on the hydraulic tank.
8. The pressure in the system has been released and lines and components can be
removed.
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.
Schematic Of Hydraulic System Components (8XG1-253, 8WJ1-90, 6NK1-155, 6RL1-59, 9WL1-131 and
1JM1-172)
(1) Rear pump. (2) Differential pressure relief valve (rear pump). (3) Differential pressure relief valve
(front pump). (4) Travel motor (right). (5) Boom drift reduction valve. (6) Main control valves. (7) Front
pump. (8) Pilot oil manifold. (9) Front swing motor. (10) Rear swing motor. (11) Stick drift reduction valve.
(12) Travel motor (left).
(8XG1-253, 8WJ1-90, 6NK1-155, 6RL1-59, 9WL1-131 and 1JM1-172)
Schematic Of Hydraulic System Components (8XG254-UP, 8WJ91-UP, 6NK156-UP, 6RL60-UP, 9WL132-
UP and 1JM173-UP)
(1) Rear pump. (2) Differential pressure relief valve (rear pump). (3) Differential pressure relief valve
(front pump). (4) Travel motor (right). (5) Boom drift reduction valve. (6) Main control valves. (7) Front
pump. (8) Pilot oil manifold. (9) Right swing motor. (10) Left swing motor. (11) Stick drift reduction valve.
(12) Travel motor (left).
(8XG254-UP, 8WJ91-UP, 6NK156-UP, 6RL60-UP, 9WL132-UP and
1JM173-UP)
NOTE: Test and adjustment of main relief valves/differential relief valves are not needed
as long as all of the pressures indicated in the above chart are normal.
Adjustment Procedures
Pressure Variation By Adjusting Screw
(8XG1-253, 8WJ1-90, 6NK1-155, 6RL1-59, 9WL1-131 and 1JM1-172)

(8XG254-UP, 8WJ91-UP, 6NK156-UP, 6RL60-UP, 9WL132-UP and
1JM173-UP)
NOTE: Values given above are approximate. Use a pressure gauge for adjustment.
Pilot Relief Valve Adjustment

Preparation
Pilot Oil Manifold Compartment

(1) Pilot oil manifold. (2) Tap. (3) Screw. (4) Pilot relief valve. (5) Locknut.
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. Connect a 4900 kPa (700 psi) pressure gauge to tap (2) of pilot oil manifold (1).
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". Make sure that engine speed under a no
load condition is 1860 ± 50 rpm with AEC switch in the OFF position. (Read rpm 3
seconds after the engine speed dial switch has been placed in position "10".)
NOTE: Normal operations (see characteristic curves) of the engine and pumps are
necessary for the pressure adjustments. If the results of the pressure adjustment are not
correct, then the engine and pump characteristic curve needs to be checked.
NOTE: Make pressure adjustments in the following sequence.
Adjustment Of Pilot Pressure

1. Loosen locknut (5).
2. Turn screw (3) until the pilot pressure at tap (2) is 3450 +200 -0 kPa (500 + 29 -0 psi).
3. Tighten locknut (5).
NOTE: Always make final pressure adjustments on pressure rise.
Disabling Sequence Valve - (8XG1-253, 8WJ1-90,

6NK1-155, 6RL1-59, 9WL1-131 and 1JM1-172)
Front Of Main Control Valves

(6) Pilot hose. (7) Sequence valve.
2. Disconnect pilot hose (6) from sequence valve (7).

NOTE: Secure pilot hose (6) from falling down out of reach.
3. Install a plug (9su/11/16-16) in the open end of pilot hose (6). Leave the port of
sequence valve (7) open to the atmospheric pressure.
Enabling Sequence Valve - (8XG1-253, 8WJ1-90, 6NK1-

155, 6RL1-UP, 9WL1-131 and 1JM1-172)

1. Remove plug (9su/11/16-16) from pilot hose (6).
2. Connect pilot hose (6) to sequence valve (7).
Adjustment Of Main Pump Margin Pressure - (8XG1-

253, 8WJ1-90, 6NK1-155, 6RL1-59, 9WL1-131 and
1JM1-172)
1. Disable sequence valve (7).
Reference: Make reference to "Disabling Sequence Valve".

Preparation

Main Pump Compartment

(8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure). (10) Pressure gauge. (11)
Pressure gauge. (12) Tap (load pressure in boom/travel circuits). (13) Hose. (14) Tap (load pressure in
stick/bucket/attachment circuits). (15) Differential pressure gauge. (16) Hose.
2. To adjust the front pump, connect hose (13) of differential pressure gauge (1U5796) to
tap (9), and hose (16) to tap (12). To adjust the rear pump, connect hose (13) of
differential pressure gauge (1U5796) to tap (8) and hose (16) to tap (14).
Adjustment

(17) Locknut (front pump). (18) Screw (front pump). (19) Locknut (rear pump). (20) Screw (rear pump).
1. To adjust the front pump margin pressure:

a. With the engine running at high idle and power mode selector in Mode III position,
very slowly move the boom control lever to PARTIAL BOOM RAISE position until the
boom just starts to move up, and hold the control lever at this position.
NOTE: The margin pressure at pressure gauge (11) will read too low if the boom control
lever is moved too fast and will read too high if the lever is moved to slow. Maintain the
position of the boom control lever once the boom starts to raise.
b. Check to see that pressure gauge (11) reads 1960 ± 100 kPa (285 ± 14 psi).
c. If not, loosen locknut (17) and turn screw (18) until pressure gauge (11) reads 1960 ±
100 kPa (285 ± 14 psi). Tighten locknut (17).
2. To adjust the rear pump margin pressure:
a. With the engine running at high idle and power mode selector in MODE III position,
very slowly move the stick control lever to PARTIAL STICK IN position until the stick
just starts to move in, and hold the control lever at this position.
b. Check to see pressure gauge (11) reads 1960 ± 100 kPa (285 ± 14 psi).
c. If not, loosen locknut (19) and turn screw (20) until pressure gauge (11) reads 1960 ±
100 kPa (285 ± 14 psi). Tighten locknut (19).
3. After pressure adjustment, reconnect pilot hose (6) to sequence valve (7).
NOTE: Pressure gauge (10) reads the main pump delivery pressure setting.
NOTE: Main pump delivery pressure varies with a change in margin pressure. After
adjustment of main pump margin pressure, be sure to readjust the delivery pressure in
accordance with "Adjustment Of Delivery Pressure" given later.
Adjustment Of Main Pump Margin Pressure -

(8XG254-Up, 8WJ91-Up, 6NK156-Up, 6RL60-Up,
9WL132-Up and 1JM173-Up)
Preparation (Rear Pump)

(1) Front pump load signal tee. (2) Load signal hose from main control valve. (3) Tees. (4) Crossover load
signal hose. (5) Front pump differential relief valve hose. (6) Rear pump system pressure test port. (7) Rear
pump load signal pressure test port.
Main Control Valve Compartment

(8) Boom raise pilot line.
Illustration of Tool Layout 1 (Boom Raise Pilot Line)
Illustration of Tool Layout 2 (Rear Pump Connections)
2. Connect tee, hose and pressure gauge into boom raise pilot line (8) in accordance with
layout illustration 1.
3. Install necessary tools in accordance with tool layout 2.
a. Disconnect front pump load signal hoses from tee (1). Leave tee (1) open to air. Using
two tees (3) connect load signal hose (2) from main control valve, load signal crossover
hose (4) and front pump differential relief valve hose (5).
b. Connect differential pressure gauge to rear pump system pressure test port (6) and load
signal pressure test port (7). Load signal pressure to front pump differential valve is
necessary to prevent differential valve from dumping.
Adjustment (Rear Pump)

(17) Locknut (front pump). (18) Screw (front pump). (19) Locknut (rear pump). (20) Screw (rear pump).
1. To adjust the rear pump margin pressure:
move the boom control lever to PARTIAL BOOM RAISE position and hold boom
activation pressure at 1000 kPa (150 psi psi).
b. Check to see that differential pressure gauge reads 1960 ± 100 kPa (285 ± 14 psi).
c. If not, loosen locknut (19) and turn screw (20) until pressure gauge reads 1960 ± 100
kPa (285 ± 14 psi). Tighten locknut (19).
2. After pressure adjustment, reconnect hoses to tees as connected before.
Preparation (Front Pump)

(3) Tees. (4) Crossover load signal hose. (9) Rear pump load signal tee. (10) Rear pump differential relief
valve hose. (11) Front pump system pressure test port. (12) Rear pump load signal pressure test port.

(8) Boom raise pilot line.
Illustration of Tool Layout 1 (Boom Raise Pilot Line)
Illustration of Tool Layout 2 (Front Pump Connections)
2. Connect tee, hose and pressure gauge into boom raise pilot line (8) in accordance with
layout illustration 1.
3. Install necessary tools in accordance with tool layout 2.
a. Disconnect rear pump differential relief valve hose (10) and load signal crossover hose
(4) from connector (9). Leave connector open to air. Using two tees (3) connect load
signal crossover hose (4) rear pump differential relief valve hose (10).
b. Connect differential pressure gauge to front pump system pressure test port (11) and
load signal pressure test port (12). Load signal pressure to rear pump differential valve is
necessary to prevent differential valve from dumping.
1. To adjust the front pump margin pressure:
move the boom control lever to PARTIAL BOOM RAISE position and hold boom
activation pressure at 1000 kPa (150 psi psi).
b. Check to see that differential pressure gauge reads 1960 ± 100 kPa (285 ± 14 psi).
c. If not, loosen locknut (17) and turn screw (18) until pressure gauge reads 1960 ± 100
kPa (285 ± 14 psi). Tighten locknut (17).
2. After pressure adjustment, reconnect hoses to tees as connected before.
3. Remove tap from boom raise pilot line.
NOTE: Main pump delivery pressure varies with a change in margin pressure. After
adjustment of main pump margin pressure, be sure to readjust the delivery pressure in
accordance with "Adjustment Of Delivery Pressure" given later.
Adjustment Of Line Relief Valve Pressure - (8XG1-253,
8WJ1-90, 6NK1-155, 6RL1-59, 9WL1-131 and
1JM1-172)
Preparation
Main Control Valves

(21) Line relief valve (bucket cylinder head end). (22) Line relief valve (stick cylinder head end). (23)
Signal relief valve (stick/bucket/attachment circuits). (24) Signal relief valve (travel circuit). (25) Line
relief valve (bucket cylinder rod end). (26) Signal relief valve (boom circuit). (27) Line relief valve (boom
cylinder rod end).
Signal Relief Valve (Boom Circuit)
(26) Signal relief valve (boom circuit). (28) Locknut. (29) Screw.
Signal Relief Valve (Stick, Bucket, Attachment And Travel Circuits)

(23) Signal relief valve (stick, bucket, attachment). (24) Signal relief valve (travel). (30) Locknut. (31)
Screw.
(8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).

4. Loosen locknut (28) of signal relief valve (26) and tighten screw (29) 1/2 turn. Tighten
locknut (28).
5. Loosen locknut (30) of signal relief valves (23) and (24) and tighten screw (31) one
turn. Tighten locknut (30).
6. Attach 49 000 kPa (7100 psi) pressure gauge to tap (8) or (9). Tap (8) is for the rear
pump. Tap (9) is for the front pump.
7. Place the power mode selector switch in Mode III position. Place the engine speed dial
at position "2".
Boom, Stick, And Bucket Line Relief Valve Adjustment Procedure
Near Boom Base

(32) Boom drift reduction valve. (33) Line relief valve (boom cylinder head end). (34) Locknut. (35) Cap.

(34) Locknut. (35) Cap. (36) Stick drift reduction valve. (37) Line relief valve (stick cylinder rod end).
Line Relief Valve

(34) Locknut. (35) Cap. (38) Screw.
1. Fully operate the boom, stick and bucket controls and read the pressure gauge attached
at tap (8) or (9) to check each of the following line relief valves:
a. Boom cylinder head end (33).

b. Boom cylinder rod end (27). If an appropriate location is not available for full
retraction of the boom cylinder, reverse the boom line relief valves of the head
end and rod end.
c. Stick cylinder head end (22).
d. Stick cylinder rod end (37).
e. Bucket cylinder head end (21).
f. Bucket cylinder rod end (25). Attach 49 000 kPa (7100 psi) pressure gauge at
tap (9) for checking line relief valves (33) and (27). Attach the pressure gauge at
tap (8) for adjusting line relief valves (22), (37), (21) and (25).
2. If a pressure gauge reading is not 33 300 ± 980 kPa (4850 ± 140 psi), adjust the line
relief pressure as follows:
a. Remove cap (35).
b. Loosen locknut (34) and turn screw (38) until the pressure gauge reads 33 300 ± 980
kPa (4850 ± 140 psi). Turning screw (38) clockwise increases the pressure. Turning
screw (38) counterclockwise decreases pressure.
c. Tighten locknut (34) and then install cap (35).
3. Adjust signal relief valves (23) and (26).
Reference: Make reference to the section "Adjusting Of Main Pump Delivery Pressure".
Adjustment Of Line Relief Valve Pressure - (8XG254-

Up, 8WJ91-Up, 6NK156-Up, 6RL60-Up, 9WL132-
Up and 1JM173-Up)
Preparation
Main Control Valves

Signal relief valve (boom/stick/bucket/attachment circuits). (24) Signal relief valve (travel circuit). (25)
Line relief valve (bucket cylinder rod end). (27) Line relief valve (boom cylinder rod end).
Signal Relief Valve (Boom/Stick/Bucket/Attachment Circuit)
(23) Signal relief valve (boom/stick/bucket/attachment circuit) boom circuit). (28) Locknut. (29) Screw.
Signal Relief Valve (Travel Circuits)

(24) Signal relief valve (travel). (30) Locknut. (31) Screw.
Main Pump Compartment (Typical Example)
2. Loosen locknut (30) of signal relief valves (23) and (24) and tighten screw (31) one
turn. Tighten locknut (30).
3. Attach 49 000 kPa (7100 psi) pressure gauge to tap (8) or (9). Tap (8) is for the rear
pump. Tap (9) is for the front pump.
4. Place the power mode selector switch in Mode III position. Place the engine speed dial
at position "2".
5. Record pressure at both taps.
Boom, Stick, And Bucket Line Relief Valve Adjustment Procedure
Near Boom Base

(32) Boom drift reduction valve. (33) Line relief valve (boom cylinder head end). (34) Locknut. (35) Cap.
(34) Locknut. (35) Cap. (36) Stick drift reduction valve. (37) Line relief valve (stick cylinder rod end).
Line Relief Valve

(34) Locknut. (35) Cap. (38) Screw.
1. Fully operate the boom, stick and bucket controls and read the pressure gauge attached
at tap (8) or (9) to check each of the following line relief valves:
a. Boom cylinder head end (33).

b. Boom cylinder rod end (27). If an appropriate location is not available for full
retraction of the boom cylinder, reverse the boom line relief valves of the head
end and rod end.
c. Stick cylinder head end (22).
d. Stick cylinder rod end (37).
e. Bucket cylinder head end (21).
f. Bucket cylinder rod end (25). Attach 49 000 kPa (7100 psi) pressure gauge at
tap (9) for checking line relief valves (33) and (27). Attach the pressure gauge at
tap (8) for adjusting line relief valves (22), (37), (21) and (25).
2. If a pressure gauge reading is not 33 300 ± 980 kPa (4850 ± 140 psi), adjust the line
relief pressure as follows:
a. Remove cap (35).
b. Loosen locknut (34) and turn screw (38) until the pressure gauge reads 33 300 ± 980
kPa (4850 ± 140 psi). Turning screw (38) clockwise increases the pressure. Turning
screw (38) counterclockwise decreases pressure.
c. Tighten locknut (34) and then install cap (35).
3. Adjust signal relief valves (23) and (24).
Reference: Make reference to the section "Adjusting Of Main Pump Delivery Pressure".
Travel Motor Crossover Relief Valve Pressure Adjustment Procedure.

- (8XG1-Up, 8WJ1-Up, 6NK1-Up, 6RL1-Up, 9WL1-Up and 1JM1-
Up)
Travel Brake Valve (Left Track)

(39) Adjuster. (40) Locknut. (41) Crossover relief valve (reverse travel). (42) Locknut. (43) Adjuster. (44)
Crossover relief valve (forward travel).
Crossover Relief Valve
(39) Adjuster. (40) Locknut. (42) Locknut. (43) Adjuster.
Sprocket (Left Track) (Typical Example)

(45) Sprocket. (46) Stopper.
Preparation
2. Loosen locknut (30) of signal relief valve (24) and tighten screw (31) one turn. Tighten
locknut (30).
3. Block forward left travel by putting stopper (46) in position on the gear of sprocket
(45), as shown above.
NOTE: Run the engine at low idle and slowly move the left travel control lever to
PARTIAL FORWARD position to secure stopper (46) in sprocket (45).
4. Run the engine with the engine speed dial switch at position "10", the travel speed
control switch at HIGH (rabbit) position and the power mode selector switch at Mode III
position.
5. Slowly move the left travel control lever to FULL FORWARD position and check the
pressure of crossover relief valve (44) by reading the pressure gauge attached at tap (9).
To adjust crossover relief valve (44), loosen locknut (42) and turn adjuster (43) until the
pressure gauge reads 36 300 ± 980 kPa (5250 ± 140 psi). Tighten locknut (42).
NOTE: One revolution of adjuster (43) is equivalent to approximately 9655 kPa (1400
psi) change in pressure.
6. Position stopper (46) to block reverse left travel.
Reference: Turning adjuster (43) or (39) clockwise increase the pressure. Turning
adjuster (43) or (39) counterclockwise decreases the pressure.
NOTE: Run the engine at low idle and slowly move the left travel control lever to
PARTIAL REVERSE position to secure stopper (46) in sprocket (45).
7. Slowly move the left travel control lever to FULL REVERSE position and check the
pressure of crossover relief valve (41) by reading the pressure gauge attached at tap (9).
To adjust crossover relief valve (41), loosen locknut (40) and turn adjuster (39) until the
pressure gauge reads 36 300 ± 980 kPa (5250 ± 140 psi). Tighten locknut (40).
NOTE: One revolution of adjuster (43) is equivalent to approximately 9655 kPa (1400
psi) change in pressure.
8. Adjust the pressure of crossover relief valves of the right travel motor in the same
manner as described for the left travel motor crossover relief valves.
9. Adjust signal relief valve (24) to the correct setting. See the section, "Adjustment Of
Main Pump Delivery Pressure".
Adjustment Of Main Pump Delivery Pressure - (8XG1-

253, 8WJ1-90, 6NK1-155, 6RL1-59, 9WL1-131 and
1JM1-172)
NOTE: Main pump delivery pressure setting is set by adjusting each of the signal relief
valves. Run engine at high idle with power mode selector switch set at MODE III
position.
Main Control Valves
Signal relief valve (stick/bucket/attachment circuits). (24) Signal relief valve (travel circuit). (25) Line
relief valve (bucket cylinder rod end). (26) Signal relief valve (boom circuit). (27) Line relief valve (boom
cylinder rod end).

1. Release the pressure in the hydraulic system.
Reference: Make reference to the section "Release Of Pressure In The Hydraulic

System".

4. To adjust the front pump delivery pressure;
Sprocket (Left Track)

a. Block forward left travel by putting stopper (46) in position on the gear of left track
sprocket (45), as shown above. Slowly move the left travel control lever to FULL
FORWARD position and check the delivery pressure of the front pump by reading the
pressure gauge attached at tap (9).

b. To adjust the delivery pressure, loosen locknut (30) of signal relief valve (24) and turn
screw (31) until the pressure gauge at tap (9) reads 34 300 ± 490 kPa (5000 ± 72 psi).
Tighten locknut (30).
Signal Relief Valve (Stick, Bucket, Attachment And Travel Circuits)
(23) Signal relief valve (stick, bucket, attachment). (24) Signal relief valve (travel). (30) Locknut. (31)
Screw.
c. Slowly move the boom control lever to boom FULL RAISE position and check the
delivery pressure of the front pump by reading the pressure gauge attached at tap (9).
Signal Relief Valve (Boom Circuit)

d. To adjust the delivery pressure, loosen locknut (28) of signal relief valve (26) and turn
Reference: Turning screw (31) or (29) clockwise increase the pressure. Turning screw
(31) or (29) counterclockwise decreases the pressure.
5. To adjust the delivery pressure of the rear pump slowly move the stick control lever to
stick FULL IN position and check the delivery pressure of the rear pump by reading the
pressure gauge at tap (8).
To adjust the delivery pressure, loosen locknut (30) of signal relief valve (23) and turn
Adjustment Of Main Pump Delivery Pressure -

(8XG254-UP, 8WJ91-UP, 6NK156-UP, 6RL60-UP,
9WL132-UP and 1JM173-UP)
NOTE: Main pump delivery pressure setting is set by adjusting each of the signal relief
valves. Run engine at high idle with power mode selector switch set at MODE III
position.
Main Control Valves

Signal relief valve (boom/stick/bucket/attachment circuits). (24) Signal relief valve (travel circuit). (25)
Line relief valve (bucket cylinder rod end). (27) Line relief valve (boom cylinder rod end).
1. Release the pressure in the hydraulic system.
Reference: Make reference to the section "Release Of Pressure In The Hydraulic

System".
2. To adjust the front pump delivery pressure;

a. Block forward left travel by putting stopper (46) in position on the gear of left track
sprocket (45), as shown above. Slowly move the left travel control lever to FULL
FORWARD position and check the delivery pressure of the front pump by reading the
pressure gauge attached at tap (9).

NOTE: To adjust the delivery pressure, loosen locknut (30) of signal relief valve (24)
and turn screw (31) until the pressure gauge at tap (9) reads 34 300 ± 490 kPa (5000 ± 72
psi). Tighten locknut (30).
Signal Relief Valve (Travel Circuits)
(24) Signal relief valve (travel). (30) Locknut. (31) Screw.
b. Slowly move the boom control lever to boom FULL RAISE position and check the
delivery pressure of the front pump by reading the pressure gauge attached at tap (9).
Signal Relief Valve (Boom/Stick/Bucket/Attachment Circuit)

NOTE: To adjust the delivery pressure, loosen locknut (28) of signal relief valve (23)
and turn screw (29) until the pressure gauge at tap (9) reads 31 400 ± 490 kPa (4550 ± 72
psi). Tighten locknut (28).
Reference: Turning screw (31) or (29) clockwise increase the pressure. Turning screw
(31) or (29) counterclockwise decreases the pressure.
Replacement Of Differential Relief Valves And Main

Relief Valves - (8XG1-253, 8WJ1-90, 6NK1-155,
6RL1-59P, 9WL1-131 and 1JM1-172)

(47) Differential relief valve (front pump). (48) Differential relief valve (rear pump).
Main Control Valves

(49) Main relief valve (in right body). (50) Main relief valve (in left body).
NOTE: Check and/or adjustment of differential relief valves and main relief valves is not
needed as long as all of the pressures checked in the previous procedures are normal. Use
a new differential relief valve and/or main relief valve for replacement when the
following problems occur:
1. The pump delivery pressure is normal, but all of the pressures of the line relief
valves (27), boom cylinder head end (33), left travel crossover relief valves (41),
(44) and right travel crossover relief valves are too low.
Main Control Valves

(21) Line relief valve (bucket cylinder head end). (22) Line relief valve (stick cylinder head end).
(23) Signal relief valve (stick/bucket/attachment circuits). (24) Signal relief valve (travel circuit).
(25) Line relief valve (bucket cylinder rod end). (26) Signal relief valve (boom circuit). (27) Line
relief valve (boom cylinder rod end).
If this problem occurs, first replace differential relief valve (47). If the problem
still exists, then replace main relief valve (50).
2. The pump delivery pressure is normal, but all of the pressures of line relief
valves (21), (22), (25) and stick cylinder rod end (37) are too low.
Replacement Of Differential Relief Valves And Main
Relief Valves - (8XG254-Up, 8WJ91-Up, 6NK156-
Up, 6RL60-Up, 9WL132-Up and 1JM173-Up)
Main Pump Compartment (Viewed From Bottom)

(47) Differential relief valve (front pump, boom/travel circuits). (48) Differential relief valve (rear pump,
stick/bucket/attachment circuits).
Main Control Valves (Viewed From Machine Front)

Signal relief valve (boom/stick/bucket/attachment). (24) Signal relief valve (travel). (25) Line relief valve
(bucket cylinder rod end). (27) Line relief valve (boom cylinder rod end). (49) Main relief valve (right
body, stick/bucket/attachment circuits). (50) Main relief valve (left body, boom/travel circuits).
NOTE: Check and/or adjustment of differential relief valves and main relief valves is not
needed as long as all of the pressures checked in the previous procedures are normal. Use
a new differential relief valve and/or main relief valve for replacement when the
following problems occur:
1. The pump delivery pressure is normal, but all of the pressures of the line relief
valves (27), boom cylinder head end (33), left travel crossover relief valves (41),
(44) and right travel crossover relief valves are too low.
2. The pump delivery pressure is normal, but all of the pressures of line relief
valves (21), (22), (25) and stick cylinder rod end (37) are too low.
Adjustment Of Sequence Valve Pressure - (8XG1-253,

8WJ1-90, 6NK1-155, 6RL1-59P, 9WL1-131 and
1JM1-172)
NOTE: There are two procedure options for adjustment of the sequence valve.
Adjustment Procedure Option 1

Illustration Of Flow Meter Tool Layout (For Sequence Valve Pressure Test)
(1) Connector (main control valves). (2) Pilot hose (travel line). (3) Elbow (main control valves). (4) Pilot
hose (stick line).

(1) Connector (main control valves). (2) Pilot hose. (3) Elbow. (4) Pilot hose. (5) Coupler. (6) Swivel tee.
(7) Swivel tee. (8) Cap.
Preparation
2. Disconnect pilot hose (4) from elbow (3).
3. Connect tees (8T8902) (6) and (7) to elbow (3).
4. Connect pilot hose (4) to swivel tee (7).
5. Connect coupler (6V4143) (5) to swivel tee (6).
6. Attach a 4900 kPa (700 psi) pressure gauge to coupler (5).
7. Disconnect pilot hose (2) from connector (1). Install cap (6V9829) (8) on connector
(1).
8. Connect pilot hose (2) to swivel tee (7).
9. Attach a 49 000 kPa (7100 psi) pressure gauge to each of taps (9) and (10). the tee.
10. Run the engine at 1860 ± 50 rpm under no load. (Read rpm an elapse of three seconds
after the engine speed dial has been placed in position "10".)
Adjustment
Sequence Valve
(2) Pilot hose. (4) Pilot hose. (11) Locknut. (12) Screw.
1. Move the stick control lever IN until the stick cylinder reaches its full extension
position. Return the stick control lever to the NEUTRAL position.
2. Slowly move the stick control lever from the NEUTRAL position toward the stick IN
position.
3. Hold the stick control lever at the position where the readings of the pressure gauges at
taps (9) and (10) have just begun to differ from each other.
4. Loosen locknut (11) and turn screw (12) until the total pressure reading of the pressure
gauge connected to coupler (5) is 4900 ± 200 kPa (700 ± 28 psi). Turning screw (12)
clockwise, increases the pressure. Turning screw (12) counterclockwise, decreases the
pressure.
5. Tighten locknut (11) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).

Adjustment Procedure Option 2

(1) Connector. (2) Pilot hose. (3) Elbow. (4) Pilot hose.

Preparation
2. Disconnect pilot hose (4) from elbow (3).
3. Connect a swivel tee (8T8902) between pilot hose (4) and elbow (3).
4. Connect a coupler (6V4143) to swivel tee (8T8902).
5. Attach a 4900 kPa (700 psi) pressure gauge to the coupler.
6. Disconnect pilot hose (2) from connector (1).
7. Install a swivel tee (8T8902) between pilot hose (2) and connector (1).
8. Connect a coupler (6V4143) to swivel tee (8T8902).
9. Attach a 4900 kPa (700 psi) pressure gauge to the coupler.

10. Block the forward left travel by putting stopper (14) in position on the gear of
sprocket (13).
11. Attach a 49000 kPa (7100 psi) pressure gauge to each of taps (9) and (10). the tee.
12. Run the engine at 1860 ± 50 rpm under no load. (Read rpm an elapse of three seconds
after the engine speed dial has been placed in position "10".)
Adjustment
Sequence Valve
(2) Pilot hose. (4) Pilot hose. (11) Locknut. (12) Screw.
1. Move the travel control lever to the FULL FORWARD position.
2. Slowly move the stick control lever from the NEUTRAL position to the stick IN
position.
3. Hold the stick control lever at the position where the readings of the pressure gauges at
taps (9) and (10) have just begun to differ from each other.
4. Loosen locknut (11) and turn screw (12) until the total pressure reading of the pressure
gauges connected to pilot hoses (4) and (2) is 4900 ± 200 kPa (700 ± 28 psi). Turning
screw (12) clockwise, increases the pressure. Turning screw (12) counterclockwise,
decreases the pressure.
Adjustment Of Swing Relief Valve Pressure

Swing Pump Compartment
(1) Swing pump. (2) Tap (swing pump delivery pressure).
Pilot Oil Manifold

(4) Swing parking brake hose.
Front Swing Motor Compartment

(3) Relief valve (left swing). (4) Front swing motor. (5) Relief valve (right swing). (6) Locknut. (7)
Adjuster.
Preparation
2. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (2) of swing pump (1).
3. Remove swing parking brake line (4) at the pilot manifold.

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
1. Slowly move the swing control lever to the FULL RIGHT SWING position.
2. Loosen locknut (6) of relief valve (5) and turn adjuster (7) until the pressure gauge at
tap (2) reads 27 500 ± 490 kPa (4000 ± 72 psi). Tighten locknut (6) to a torque of 155 ±
29 N·m (115 ± 22 lb ft).
Reference: Turning adjuster (7) clockwise increase the pressure. Turning adjuster (7)
counterclockwise decreases the pressure.
3. To adjust relief valve (3), slowly move the swing control lever to the FULL LEFT
SWING position.
4. Adjust relief valve (3) in the same manner as above Step 2.
Adjustment Of Automatic Travel Speed Change Valve

Pressure
Preparation
(1) Tap (front pump).
Pilot Oil Manifold Compartment (In Rear Of Main Control Valves)

(2) Pilot oil manifold. (3) Tap.
Travel Motor (Left Track)

(4) Signal pressure line. (5) Coupler. (6) Swivel tee. (7) Connector.
2. Install a 49 000 kPa (7100 psi) pressure gauge at tap (1) on the front pump.
3. Install a 4900 kPa (700 psi) pressure gauge at tap (3) on the pilot oil manifold (2).
4. Disconnect signal pressure line (4) from connector (7).
5. Install swivel tee (6) between pressure line (4) and connector (7).
6. Install coupler (5) to swivel tee (6).
7. Attach a 4900 kPa (700psi) pressure gauge to coupler (5).

8. Start the engine and place the power mode selector switch at Mode III position.
Maintain a maximum no load speed of 1860 ± 50 rpm with the AEC switch OFF.
9. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).

10. Block the forward left travel by putting stopper (9) in position on the gear of sprocket
(8).
11. Place the travel speed control switch in the HIGH (rabbit sign) position.
12. Check the pilot pressure on the gauge attached to tap (3). The pressure gauge should
read 3450 kPa (500 psi).
Adjustment
Automatic Travel Speed Control Valve (In Rear Of Main Control Valves)
(8) Locknut. (9) Screw.
1. While reading the pressure gauges connected to signal pressure line (4) and tap (1),
slowly move the left travel control lever to the FORWARD position. When system
pressure at tap (1) reads 33 800 ± 490 kPa (4900 ± 72 psi), the pressure gauge connected
to signal pressure line (4) should be reduced to 0 kPa (0 psi).
NOTE: This pressure is indicated when the automatic travel speed change valve causes
the travel motor to shift to LOW speed.
2. If the pressure gauge connected to signal pressure line (4) does not read 0 kPa (0 psi) at
the same time the gauge at system pressure at tap (1) reads 33 800 ± 490 kPa (4900 ± 72
psi), then adjust the automatic travel speed change valve as follows:
NOTE: Always make the final pressure adjustments during the pressure rise.
a. Loosen locknut (10) and turn screw (11) until the pressure gauge connected to signal
pressure line (4) reads 0 kPa (0 psi) when the pressure gauge at tap (1) reads 33 800 ±
490 kPa (4900 ± 72 psi).
NOTE: Turning screw (9) clockwise increases the pressure. Turning screw (9)
counterclockwise decreases the pressure.
b. Tighten locknut (10) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).
3. Repeat Step 1.
4. Move the left travel control lever to the FULL FORWARD position and then slowly
return it to the NEUTRAL position until the reading of pressure gauge connected to tap
(1) decreases to 12 300 ± 490 kPa (1775 ± 72 psi).
5. The pressure in the gauge connected to signal pressure line (4) reads 3450 kPa (500
psi).
NOTE: This pressure is indicated when the automatic travel speed change valve causes
the travel motor to shift to HIGH speed.
Pump Flow Tests
Controller Compartment
(1) Controller alarm lamp. (2) Controller.
Right Console
(3) Monitor. (4) Monitor panel.
NOTE: Before starting pump flow tests, be sure the action alarm indicators on controller
(2) and monitor panel (4) indicate Normal.
NOTE: If the 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. Then the "Pump Flow Test" should be made.
NOTE: If the operational tests indicate a implement speed problem common to both the
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 1 (Constant Horsepower Control Test) (Main Pump)
(1) Delivery hose (front pump). (2) Delivery hose (rear pump). (3) Front pump. (4) Rear pump. (5) Return
hose. (6) Return line.
Illustration Of Flow Meter Tool Layout 2 (Constant Horsepower Control Test) (Main Pump)
(7) Tee (front pump load sensing regulator). (8) Tee (rear pump load sensing regulator). (9) Load signal
hose (front pump). (10) Load signal hose (rear pump).
Preparation (Front Pump) - (8XG1-253, 8WJ1-90, 6NK1-155, 6RL1-59,
9WL1-131 and 1JM1-172)
Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Front Pump)
(1) Delivery hose. (3) front pump. (5) Return hose. (6) Return line. (7) Tee. (9) Load signal hose. (11)
Flange (1P4582). (12) Cover (2J5608). (13) Main control valves. (14) Flange (5P8077). (15) Plate
(7I7132). (16) Flow meter (4C9910). (17) Pressure gauge. (18) Tap (power shift pressure). (19) Tap (front
pump delivery pressure). (20) Hose (6V3014). (21) Cap (6V9829). (22) Plug (6V9508). (23) Swivel tee
(8T8902). (24) Pressure gauge. (25) Swivel tee (8T8902).

(3) Front pump. (4) Rear pump. (7) Tee. (8) Tee. (9) Load signal hose. (10) Load signal hose. (18) Tap
(power shift pressure). (19) Tap (front pump delivery pressure). (26) Tap (rear pump delivery pressure).

(5) Return hose. (6) Return line. (13) Main control valves.
Flow Meter
(16) Flow meter (4C9910). (27) Multitach (6V2100). (28) Valve.
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).
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 layout illustrations 1 and 2.
a. Disconnect delivery hose (1) from front pump (3).
b. Install plate (7I7132) (15) and flange (5P8077) (14) to the end of delivery hose (1).
c. Disconnect return line (6) from return hose (5).
d. Install cover (2J5608) (12) and flange (1P4582) (11) to the end of return line (6).
e. Connect flow meter (4C9910) (16) between front pump (3) and return hose (5).
f. Disconnect load signal hose (9) of main control valves (13) from front pump load
sensing tee (7). Install plug (6V9508) (22) in the end of load signal hose (9).
g. Connect swivel tees (23) and (25) to tee (7). Install cap (6V9829) (21) in swivel tee
(25).
h. Connect hose (6V3014) (20) between front pump tap (19) and swivel tee (23).
i. Install pressure gauge (8T0861) (24) at swivel tee (25). [A 49 000 kPa (7100 psi)
pressure gauge can be used in place of 8T0861 pressure gauge.]
4. Install 4900 kPa (700 psi) pressure gauge (17) at tap (18).
5. Install multitach group (6V2100) (27) on to the engine. This is to read the engine speed
rpm.
6. Start the engine and place the power mode selector switch in mode III position.
7. Place the engine speed dial at position "10" and maintain the maximum no load speed
at 1860 ± 50 rpm with the AEC switch OFF. (Read the rpm three seconds elapsed time
after the engine speed dial has been placed in position "10".
9. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To do this, move the
stick IN and OUT its full travel several times.
Preparation (Front Pump) - (8XG254-UP, 8WJ91-UP, 6NK156-UP,
6RL60-UP, 9WL132-UP and 1JM173-UP)
Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Front Pump)
(1) Delivery hose. (3) Front pump. (5) Return hose. (6) Return line. (7) Tee. (8) Tee. (9) Load signal hose
from main control valve. (10) Load sensing crossover hose. (11) Flange (1P4582). (12) Cover (2J5608).
(13) Main control valves. (14) Flange (5P8077). (15) Plate (7I7132). (16) Flow meter (4C9910). (17)
Pressure gauge. (18) Tap (power shift pressure). (19) Tap (front pump delivery pressure). (20) Hose
(6V3014). (21) Cap (6V9829). (22) Plug (6V9508). (23) Swivel tee (8T8902). (24) Pressure gauge. (25)
Swivel tee (8T8902). (28) Rear pump.

(3) Front pump. (4) Rear pump. (7) Tee. (8) Tap (front pump load signal pressure). (9) Load signal hose
from main control valve. (10) Crossover load signal hose. (18) Tap (power shift pressure). (19) Tap (front
pump delivery pressure). (26) Tap (rear pump delivery pressure).
Illustration of Flow Meter Tool Layout 4

Flow Meter
(16) Flow meter (4C9910). (27) Multitach (6V2100). (28) Valve.

3. Install the following tools in accordance with layout illustrations 1.
a. Disconnect delivery hose (1) from front pump (3).

e. Connect flow meter (4C9910) (16) between front pump (3) and return hose (5).
f. Disconnect load signal hose (9) from front pump load signal tee (7). Disconnect load
signal crossover line (10) from rear pump (28) and plug line. Connect load signal line (9)
from main control valve to rear pump (28).
g. Install tools in accordance with tool layout 4.
h. A 49 000 kPa (7100 psi) pressure gauge can be used in place of 8T0861 pressure
gauge.
4. Install 4900 kPa (700 psi) pressure gauge (17) at power shift tap (18).
5. Install multitach group (6V2100) (27) on to the engine. This is to read the engine speed
rpm.
7. Place the engine speed dial at position "10" and maintain the maximum no load speed
at 1860 ± 50 rpm with the AEC switch OFF. (Read the rpm three seconds elapsed time
after the engine speed dial has been placed in position "10".
Preparation (Rear Pump) - (8XG1-253, 8WJ1-90, 6NK1-155, 6RL1-59,
9WL1-131 and 1JM1-172)
Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Rear Pump)
(2) Delivery hose. (4) Rear pump. (5) Return hose. (8) Tee. (10) Load signal hose. (13) Main control
valves. (14) Flange (5P8077). (15) Plate (7I7132). (16) Flow meter (4C9910). (17) Pressure gauge. (20)
Hose (6V3014). (21) Cap (6V9829). (22) Plug (6V9508). (23) Swivel tee (8T8902). (24) Pressure gauge.
(25) Swivel tee (8T8902). (26) Tap.
Perform the same procedure 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.
a. Disconnect delivery hose (2) from rear pump (4).
c. Connect flow meter (4C9910) (16) between rear pump (4) and return hose (5).
d. Disconnect load signal hose (10) of main control valves (13) from load sensing
regulator tee (8). Install plug (6V9508) (22) in the end of load signal hose (10).
e. Connect swivel tees (23) and (25) to tee (8). Install cap (6V9829) (21) in swivel tee
(25).
f. Connect hose (6V3014) (20) between rear pump tap (26) and swivel tee (23).
g. Install pressure gauge (8T0861) (24) at swivel tee (25). [A 49 000 kPa (7100 psi)
pressure gauge can be used in place of 8T0861 pressure gauge.]
Preparation (Rear Pump) - (8WJ91-UP, 6NK156-UP, 9WL132-UP and

1JM173-UP)

(7) Tap (rear pump load signal). (9) Tap (rear pump load signal pressure). (10) Load signal crossover hose.
(18) Tap (power shift pressure). (26) Tap (rear pump system pressure).
Illustration of Tool Layout 2
Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Rear Pump)
(2) Delivery hose. (4) Rear pump. (5) Return hose. (7) Load sensing port. (8) Tee. (10) Load signal
crossover hose. (11) Flange (1P4582). (12) Cover (2J5608). (13) Main control valves. (14) Flange
(5P8077). (15) Plate (7I7132). (16) Flow meter (4C9910). (17) Pressure gauge. (20) Hose (6V3014). (21)
Cap (6V9829). (22) Plug (6V9508). (23) Swivel tee (8T8902). (24) Pressure gauge. (25) Swivel tee
(8T8902). (26) Tap (rear pump system pressure). (28) Front Pump.
Perform the same procedure 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.
a. Disconnect delivery hose (2) from rear pump (4).
c. Connect flow meter (4C9910) (16) between rear pump (4) and return hose (5).
d. Install cover (2J5608) (12) and flange (1P4582) (11) to the end of return line.
e. Disconnect load signal crossover line (10) from front pump (28). Install plug (6V9508)
in the open end of load signal hose (10).
f. Install pressure gauge (8T0861) (24) to swivel tee. [A 49 000 kPa (7100 psi) pressure
gauge can be used in place of 8T0861 pressure gauge.]
g. Connect hose from system pressure tap (26) to load signal tap (9).
h. Connect hose from load signal tee (7) to tee (8) as per tool layout 2. Cap open end of
tee.
Flow Test
NOTE: Perform front and rear pump flow test one at a time.
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.
1. With the engine running, start the service program "Calibration Mode" and maintain
the power shift pressure at a constant pressure of 1500 ± 50 kPa (220 ± 7 psi). The power
shift pressure is read at tap (18) using pressure gauge (17).
NOTE: During test, never try to turn the starter switch OFF to prevent any change in
power shift pressure.
2. Slowly turn valve (28) of flow meter (16) clockwise and record pump flow at each of
following pressure points. Use pressure gauge (24) for this pressure reading.
P-Q Characteristic Curve [At 1500 kPa (220 psi) Power Shift Pressure]
NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To
get more accurate test results, each of measurements should be corrected by calculating
as follows.
Flow corrected = (Flow measured × 1800) ÷ RPM measured
1. Any flow readings must be done only in upstroke.

2. The pump flow changes approximately 30 liter/min. (7.9 U.S. gpm) for each
100 kPa (14 psi) of power shift pressure.
To prevent damages to the main pump and associated circuit

components because of too high pump delivery pressure, make sure to
reconnect each of load signal hoses (17) and (28) to its original pump
regulator after completion of the main pump flow test.
Adjustment Of Main Pump Flow

If flow measurements are out of specifications, adjust the flow as follows.
NOTE: Any flow variation per one turn of a setscrew should be used as a guide only.
Always use a flow meter to adjust the pump flow.
Main Pumps
NOTE: Main pump flow adjustment procedure for each of the front and rear pumps is
the same. Description is given to the front pump as a typical example.
Front Pump
(1) Locknut. (2) Setscrew. (3) Setscrew. (4) Locknut.
Flow Adjustment Under Constant Horsepower Control
2. Turn setscrew (3) until adjusted to the correct specification. Turning setscrew (3)
clockwise decreases flow rate. Turning setscrew (3) counterclockwise increases flow rate.
One turn of setscrew (3) changes flow rate approximately 50 liter/min (13 U.S. gpm) at a
system pressure of 25 500 kPa (3700 psi).
Maximum Flow Adjustment
One turn of setscrew (3) changes flow rate approximately 34 liter/min. (9.0 U.S. gpm).
Swing Pump Constant Horsepower Control Test

Illustration Of Flow Meter Tool Layout 3 (Constant Horsepower Control Test) (Swing Pump)
(1) Delivery hose. (2) Swing pump. (3) Return hose. (4) Return line.
Illustration Of Flow Meter Tool Layout 4 (Constant Horsepower Control Test) (Swing Pump)
(5) Pilot hose (swing power control). (6) Pilot hose (positive flow control). (7) Block.
Preparation
Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Swing Pump)
(1) Delivery hose. (2) Swing pump. (3) Return hose. (5) Pilot hose (swing power control). (6) Pilot hose
(positive flow control). (7) Block (pilot pump). (8) Swing control valve. (9) Flange (1P4582). (10) Cover
(2J5608). (11) Pilot oil manifold. (12) Pressure gauge. (13) Plate (7I7132). (14) Flange (5P8077). (15) Flow
meter (4C9910). (16) Plug (6V9508). (17) Pressure gauge. (18) Swivel tee (8T8902). (19) Swivel tee
(8T8902). (20) Cap (6V9829). (21) Pilot pump. (22) Regulator. (23) Hose (6V3014). (24) Hose (6V3014).
(2) Swing pump. (7) Block. (21) Pilot pump. (25) Tap (swing pump delivery pressure). (26) Tap (pilot
pump delivery pressure).

(1) Delivery hose. (2) Swing pump. (5) Pilot hose. (6) Pilot hose. (21) Pilot pump. (22) Regulator. (26) Tap
(pilot pump delivery pressure).

(11) Pilot oil manifold. (28) Tap (pilot pump delivery pressure).
Flow Meter
(15) Flow meter (4C9910). (29) Multitach group (6V2100). (30) Valve.

3. Install necessary tools in accordance with the layout Illustrations 3 and 4 as follows:
a. Disconnect delivery hose (1) from swing pump (2).
b. Install plate (7I7132) (13) and flange (5P8077) (14) to end of delivery hose (1).
e. Connect flow meter (4C9910) (15) between swing pump (2) and return hose (3).
f. Disconnect pilot hoses (5) and (6) from swing pump regulator (22). Install plug
(6V9508) (16) in to the open end of pilot hoses (5) and (6).
g. Remove tap (26) from block (7) of pilot pump (21).

h. Connect swivel tees (8T8902) (18) and (19) to the port of block (7) where tap (26) was
removed. Install cap (6V9829) (20) to one end of swivel tee (19).
i. Connect hose (6V3014) (23) between swivel tee (18) and the open port of regulator
(22) where pilot hose (5) was removed.
j. Connect hose (6V3014) (24) between swivel tee (19) and the open port of regulator
(22) where pilot hose (6) was removed.
3. Install pressure gauge (8T0861) (17) at tap (25). A 49 000 kPa (7100 psi) pressure
gauge can be used in place of a 8T0861 pressure gauge
4. Install 4900 kPa (700 psi) pressure gauge (12) to tap (28) of pilot oil manifold (11).
5. Install multitach group (6V2100) (29) on the engine. This is to read the engine speed
rpm.
7. Place the engine speed dial at position "10" and run the engine at no load speed of
1860 ± 50 rpm with AEC switch OFF. (Read rpm after a elapse of 3 seconds after the
speed dial has been placed in position "10".)
8. Place the swing lock pin in the LOCKED position.
10. Pressure gauge (12) at tap (28) should read 3450 + 200 -0 kPa (500 +29 -0 psi).
Flow Test

1. Slowly turn valve (30) of flow meter (4C9910) (15) clockwise and record pump flow
at each of the following pressure points. Use pressure gauge (17) for this pressure
reading.
P-Q Characteristic Curve
get more accurate test results, each of measurements should be corrected by calculating
as follows.
Flow corrected = (Flow measured × 1800) ÷ rpm measured
1. Any flow readings must be done only in upstroke.

2. During this test, check to be sure that the high pressure cut characteristic
correctly functions. This can be done by identifying a sudden flow decrease when
the delivery pressure reaches close to 27 500 kPa (4000 psi).
3. Under the above test condition, the swing pump runs at a speed of 1913 rpm.
Swing Pump Positive Flow Control Test
Illustration Of Flow Meter Tool Layout 3 (Positive Flow Control Test) (Swing Pump)
(1) Delivery hose. (2) Swing pump. (3) Return hose. (4) Return line.
Illustration Of Flow Meter Tool Layout 5 (Positive Flow Control Test) (Swing Pump)
(5) Pilot hose (swing power control). (6) Pilot hose (positive flow control). (22) Regulator. (26) Tap (pilot
Preparation
Circuit Diagram For Flow Test (Positive Flow Control Test) (Swing Pump)
(1) Delivery hose. (2) Swing pump. (3) Return hose. (4) Return line. (5) Pilot hose (swing power control).
(6) Pilot hose (positive flow control). (8) Swing control valve. (9) Flange (1P4582). (10) Cover (2J5608).
(11) Pilot oil manifold. (12) Pressure gauge. (13) Plate (7I7132). (14) Flange (5P8077). (15) Flow meter
(4C9910). (16) Plug (6V9508). (17) Pressure gauge. (21) Pilot pump. (22) Regulator. (23) Hose (6V3014).
(26) Tap (pilot pump delivery pressure). (31) Pressure gauge.
(2) Swing pump. (7) Block. (21) Pilot pump. (25) Tap (swing pump delivery pressure). (26) Tap (pilot

(1) Delivery hose. (2) Swing pump. (5) Pilot hose. (6) Pilot hose. (21) Pilot pump. (22) Regulator. (26) Tap
(pilot pump delivery pressure).

(11) Pilot oil manifold. (28) Tap (pilot pump delivery pressure).
Flow Meter
(15) Flow meter (4C9910). (29) Multitach group (6V2100). (30) Valve.

flow meteror associated circuit components because of blocked pump
3. Install necessary tools in accordance with the layout illustrations 3 and 5 as follows:
a. Disconnect delivery hose (1) from swing pump (2).
b. Install plate (7I7132) (13) and flange (5P8077) (14) to end of delivery hose (1).

e. Connect flow meter (4C9910) (15) between swing pump (2) and return hose (3).
f. Disconnect pilot hose (5) from swing pump regulator (22). Install plug (6V9508) (16)
in to the open end of pilot hoses (5).
g. Connect hose (6V3014) (23) between tap (26) and the open port of regulator (22)
where pilot hose (5) was removed.
h. Disconnect pilot hose (6) from regulator (22). Connect pressure gauge (8T0855) (31)
between pilot hose (6) and the open port of regulator (22). A 4900 kPa (700 psi) pressure
gauge can be used in place of a 8T0855 pressure gauge.
3. Install pressure gauge (8T0861) (17) at tap (25). A 49 000 kPa (7100 psi) pressure
gauge can be used in place of a 8T0861 pressure gauge.
4. Install 4900 kPa (700 psi) pressure gauge (12) to tap (28) of pilot oil manifold (11).
5. Install multitach group (6V2100) (29) on the engine. This is to read the engine speed
rpm.
7. Place the engine speed dial at position "10" and run the engine at no load speed of
1860 ± 50 rpm with AEC switch OFF. (Read rpm after a elapse of 3 seconds after the
speed dial has been placed in position "10".)
8. Place the swing lock pin in the LOCKED position.
10. Pressure gauge (12) at tap (28) should read 3450 + 100 -0 kPa (500 +14 -0 psi).
Flow Test

1. Slowly turn valve (30) of flow meter (4C9910) (15) clockwise until the swing pump
delivery pressure is 6850 kPa (1000 psi). Read pressure gauge (17) at tap (25).
2. Gradually move the swing control lever to the RIGHT SWING position until pressure
gauge (31) reads 1370 kPa (200 psi) and hold the control lever in this position. Then
record the swing pump flow under positive flow control.
get more accurate test results, measured flow should be corrected by calculating as
follows:
Flow corrected = (Flow measured × 1800) ÷ rpm measured
Adjustment Of Swing Pump

Swing Pump
(1) Setscrew. (2) Locknut. (3) Locknut. (4) Setscrew. (5) Locknut. (6) Setscrew.
Constant Horsepower Flow Adjustment
clockwise increases flow rate. Turning setscrew (6) counterclockwise decreases flow rate.
One turn of setscrew (6) changes flow rate approximately 65 liter/min. (17 U.S. gpm) at a
system pressure of 19 600 kPa (2850 psi).
Maximum Flow Adjustment
One turn of setscrew (4) changes flow rate approximately 30 liter/min. (7.9 U.S. gpm).
Flow Adjustment Under Positive Flow Control
clockwise increases flow rate. Turning setscrew (1) counterclockwise decreases flow rate.
A half turn of setscrew (1) changes flow rate approximately 90 liter/min. (24 U.S. gpm).
NOTE: Pressure variation per one turn of a setscrew should be used as a guide only.
Always use a pressure gauge to make pressure adjustment.
Copyright 1993 - 2007 Caterpillar Inc. Tue Jun 5 15:00:39 UTC+0700 2007
All Rights Reserved.
Private Network For SIS Licensees.

Testing and Adjusting

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Testing and Adjusting

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Testing and Adjusting

365C Excavator Hydraulic System

Hydraulic System Pressure - Release

The release of hydraulic pressure in a hydraulic circuit is required before service is

 Boom hydraulic circuit

Release Of Hydraulic Pressure From A Single

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

Dispose of all fluids according to local regulations and mandates.

1. Position the machine on level ground.

3. Shut off the engine.

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

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

Release Of Hydraulic Pressure From Multiple

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

1. Position the machine on level ground.

3. Shut off the engine.

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

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

8. Start the engine.

11. Shut off the engine.

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

Purge Screws (Boom, Stick and/or Bucket Hydraulic

(3) Purge screws (one on each line)

(A) Line for the stick

(B) Line for the bucket

(C) Line for the bucket

(D) Line for the stick

Note: Dispose of drained fluid according to local regulations.

(4) Purge screws for the boom

Testing and Adjusting

Relief valve locations

(2) Right swing motor

(3) Left swing motor

(4) Main control valve

(5) Pilot manifold

(6) Travel motor (right)

(7) Travel motor (left)

(B) Boom cylinder line (head end)

(C) Stick cylinder line (head end)

(G) Signal relief valve (heavy lift and travel)

(H) Signal relief valve (boom and stick)

(I) Bucket cylinder line (rod end)

(J) Boom cylinder line (rod end)

(K) Stick cylinder line (rod end)

(L) Right swing motor (right relief valve)

(M) Right swing motor (left relief valve)

(N) Left swing motor (right relief valve)

(O) Left swing motor (left relief valve)

(P) Margin pressure adjustment screw (rear pump)

(Q) Margin pressure adjustment screw (front pump)

(R) Pilot relief valve

(W) Differential relief valve (rear pump)

(X) Differential relief valve (front pump)

(Y) Control valve for counterweight cylinder

Relief Valve Specifications

(P) Margin pressure

(B) Boom cylinder line

(J) Boom cylinder line

(L) Right swing motor

(O) Left swing motor (3910 to 4270

(V) Left travel

(U) Left travel

(T) Right travel