Pruebas y Ajustes

R1300G Load Haul Dump Hydraulic System

Número de medio -RENR6939- Fecha de publicación Fecha de actualización
03 -01/05/2007 -22/05/2007

   
i01856365

Hydraulic System Troubleshooting

SMCS - 5050-035

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.

Personal injury or death can result from escaping fluid under pressure.

Escaping fluid under pressure, even a very small pin-hole size leak, can
penetrate body tissue and cause serious injury and possible death. If
fluid is injected into your skin, it must be treated immediately by a
doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

Sudden movement or accidental starting of the machine can cause

personal injury or death to persons on or near the machine.

To prevent personal injury or death, perform the following:

Park the machine on a smooth, level surface.

Lower the work tool to the ground and engage the parking brake.

Stop the engine and remove the key.

 Block the wheels and install the steering frame lock.

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.

The main relief valve is common to the lift circuit and the tilt circuit. The lift circuit and
the tilt circuit have load check valves in the head end circuit and in the rod end circuit in
order to prevent cylinder drift during movement of the valve spool.

The line relief valves in the lift circuit and in the tilt circuit protect the components from
pressures in the circuits when the control valve is in the HOLD position.

 The oil pressure for opening the relief valves for the main system and for the
line circuits must be within the specifications. Pressures that are too low will
cause a decrease in the lifting force and in the dig characteristics. Pressures that
are too high will cause a decrease in the life of hoses and of other components.
 Circuit drift is caused by leakage past cylinder pistons, past O-ring seals in the
control valves, past load check valves that do not seat correctly or past makeup
valves that do not seat correctly. Poor adjustments of the control valves or
incorrect fit may also contribute to circuit drift.
 Cycle times that are longer than normal result from oil leakage, from pump
wear, or from the pump speed.

Troubleshooting
Problem: The implement pump makes noise and the cylinder rods do not
move evenly. There are also air bubbles in the oil.

Probable causes:

 The viscosity of the oil is incorrect.

 The main relief valve opens at low oil pressure.
 There is a loose connection of the oil line on the inlet side of the implement
pump.
  The implement pump has too much wear.

Problem: The oil temperature is too high.

Probable causes:

 The machine is being operated above the intended capacity or in ambient

temperatures that are too high for the machine's design.
 The viscosity of the oil is incorrect.
 The setting of the main relief valve is too low. This causes the main relief valve
to remain open.
 The implement pump has too much wear.
 There is a restriction in an oil passage.
 There is a leak in one or more circuits.
 The oil level is low.
 The oil is contaminated.
 The air flow through the hydraulic oil cooler is too low.
 The oil flow through the hydraulic oil cooler is too low.
 The hydraulic oil temperature sensor is faulty.
 There is air in the hydraulic oil.

Note: A problem with air in the hydraulic oil must be corrected before the hydraulic
system will operate at normal temperatures. There are two conditions that cause air to
be in the hydraulic oil:

 Return oil is flowing into the hydraulic oil tank above the level of oil that is in
the tank.
 There are leaks in the oil suction line between the implement pump and the
hydraulic oil tank.

Problem: The output of the implement pump is low.

Probable causes:

 The oil level is low.

 The viscosity of the oil is incorrect.
 The implement pump has too much wear.

Problem: The oil pressure is low.

Probable causes:
  The main relief valve opens at low oil pressure.
 The implement pump has too much wear.
 An O-ring seal in the system failed.
 The main control valve and the valve spool have an excessive amount of wear.

Problem: The attachment moves while the joystick control lever is in the
HOLD position.

Probable causes:

 The pilot control actuator on the main control valve is damaged.

 The control valve and the valve spool have an excessive amount of wear.
 A piston seal in a cylinder has an excessive amount of wear.
 There is a leak in a connection between the control valve and the moving
cylinder(s).
 A load check valve is not closing because of dirt or because of a worn seat.
 The control valve is not centering correctly.

Problem: The attachment droops when the joystick control lever is

moved from the HOLD position to the RAISE position.

Probable causes:

 The oil is too cold.

 The piston seals and/or the lift cylinders are worn.
 The load check valve is not closing because the return spring is weak or broken,
or because there is dirt or debris in the load check valve.

Problem: The hydraulic force is too low when the joystick control lever is
moved to the RAISE position or to the LOWER position.

Probable causes:

 The machine is being operated incorrectly.

 The pilot system pressure is too low.
 The main control valve is contaminated or damaged.
 The load check valve is not closing because the return spring is weak or broken,
or because there is dirt or debris in the load check valve.
 The pilot control valve is contaminated or damaged.
 The main relief valve setting is too low.
Problem: All implement functions are sluggish.

Probable causes:

 The oil level is too low.

 The implement pump is worn or damaged.
 The main relief valve setting is too low.
 The oil in the hydraulic system is contaminated.

Problem: The implement functions are erratic or intermittent.

Probable causes:

 The oil level is too low.

 The implement pump has too much wear.
 The main control valve is contaminated or damaged.
 The load check valve is not closing because the spring is weak or broken, or
because there is dirt or debris in the load check valve.
 There is air in the hydraulic oil.

Note: A problem with air in the hydraulic oil must be corrected before the hydraulic
system will operate at normal temperatures. There are two conditions that cause air to
be in the hydraulic oil:

 Return oil is flowing into the hydraulic oil tank above the level of oil that is in
the tank.
 There are leaks in the oil suction line between the hydraulic pump and the tank.

Problem: There is too much lift cylinder drift.

Probable causes:

 The piston seals and/or the lift cylinders are worn.

 The components of the main control valve are worn or damaged.
 The load check valve is not closing because the spring is weak or broken or
because there is dirt or debris in the check valve.

Problem: The hydraulic force is too low when the joystick control lever is
moved to the TILT BACK position or to the DUMP position.

Probable causes:

 The machine is being operated incorrectly.

 The settings of the line relief valves are too low.
  The piston seals and/or the tilt cylinder is worn.
 The main control valve is contaminated or damaged.
 The pilot control actuator is contaminated or damaged.
 The main relief valve setting is too low.

Problem: The lift cylinders collapse during the lift operation.

Probable causes:

 The nitrogen precharge pressure in the ride control accumulator is too low.
 The piston seals and/or the lift cylinders are worn.
 The main control valve is contaminated or damaged.
 The load check valve is not closing because the spring is weak or broken, or
because there is dirt or debris in the check valve.

Problem: There is low power to the implements.

Probable causes:

 The machine is operating above the intended capacity.

 The engine power is too low.
 The implement pump has too much wear.
 The main relief valve setting is too low.
 The settings of the line relief valves are too low.
 The piston seals and/or the cylinders are worn.
 The load check valve is damaged or contaminated.

Problem: There is too much tilt cylinder drift.

Probable causes:

 The setting of the line relief valve is too low.

 The piston seals and/or the tilt cylinder is worn.
 The components of the main control valve are worn or damaged.
 The load check valve is contaminated or damaged.

Problem: The tilt cylinder collapses during the tilt operation.

Probable causes:

 The setting of the main relief valve is too low.

  The piston seals and/or the tilt cylinder is worn.
 There is dirt or debris in the main control valve.
 The main control valve and the tilt spool mating surfaces may be worn or
damaged.
 The makeup valve is sticking.

Problem: The bucket droops during the tilt function.

Probable causes:

 The oil is too cold.

 The piston seals and/or the tilt cylinder is worn.
 The load check valve is not closing because the spring is weak or broken, or
because there is dirt or debris in the check valve.

Problem: One implement function is sluggish or nonfunctional.

Probable causes:

 The setting of the line relief valve is too low.

 The main control valve and the main control valve spools mating surfaces are
worn or damaged.

Problem: The implements are not functioning.

Probable causes:

 The pilot pump is worn or damaged.

 The implement pump has too much wear.
 The pilot relief valve is faulty or the pressure setting for the pilot relief valve is
too low.
 The selector and pressure control valve is open.
 The main relief valve setting is too low.
 The implement and steering neutralizer valve is open.

Pruebas y Ajustes
R1300G Load Haul Dump Hydraulic System

Número de medio -RENR6939- Fecha de publicación Fecha de actualización

03 -01/05/2007 -22/05/2007
   
 i01682705

Caudal de la bomba - Probar

SMCS - 5055-032-ON ; 5055-032-TB

ReferenciaPara obtener información adicional sobre la operación del sistema

hidráulico, vea las Especificaciones de la máquina correspondiente.

Esta prueba está diseñada para determinar si una bomba está funcionando dentro de los
parámetros del diseño. Se debe hacer esta prueba sólo si todos los tiempos de ciclo de
los cilindros son demasiado lentos.

Para cualquier prueba de la bomba, el flujo de la bomba a 690 kPa (100 lb/pulg2) será
mayor que el flujo de la bomba a 6.900 kPa (1.000 lb/pulg2) si la bomba opera a las
mismas rpm. El flujo de la bomba se mide en litros/min (gal. EE.UU./min.)

La diferencia entre el flujo de la bomba a las dos presiones de operación es la pérdida de

flujo.

Nota: Los valores de los ejemplos no son valores fijos para ninguna bomba específica o
estado específico de la bomba. Vea en el módulo de Especificaciones el caudal de una
bomba nueva a 690 kPa (100 lb/pulg2) y a 6.900 kPa (1.000 lb/pulg2).

Tabla 1

Método de determinar la pérdida de flujo    

   Flujo de la bomba a
  
690 kPa (100 lb/pulg2)    

−     Flujo de la bomba a
  
6.900 kPa (1.000 lb/pulg2)    

   Pérdida de flujo       

Tabla 2

Ejemplo para determinar la pérdida de flujo    

  
  
217,6 L/min (57,5 gal EE.UU./min)    

−  
  
196,8 L/min (52,0 gal EE.UU./min)    

  
  
20,8 L/min (5,5 gal. EE.UU./min.)    

La pérdida de flujo expresada en forma de porcentaje de flujo de la bomba se usa como

medida del rendimiento de la bomba.
 Tabla 3

Método para determinar la pérdida de flujo    

Pérdida de flujo (litros/min o gal.

EE.UU./min.)     Pérdida de flujo en
×     100     =    
Flujo de la bomba a porcentaje    
690 kPa (100 lb/pulg2)    

Tabla 4

Ejemplo para determinar la pérdida de flujo    

20,8 L (5,5 gal. EE.UU.)    

×     100     =     9,5%    

217,6 L/min (57,5 gal EE.UU./min)    

Prueba en la máquina
Instale un medidor de flujo. Opere el motor a velocidad alta en vacío. Mida el flujo de la
bomba a 690 kPa (100 lb/pulg2) y a 6.900 kPa (1.000 lb/pulg2). Use estos valores en la
fórmula de la tabla 5.

Tabla 5

   Flujo de la bomba a
        
690 kPa (100 lb/pulg2)       

Flujo de la bomba a
−  
6.900 kPa (1.000 lb/pulg2)  
×     100     =     Pérdida de flujo en porcentaje    
   Flujo de la bomba a
690 kPa (100 lb/pulg2)    

Prueba de banco
Si el banco de pruebas se puede operar a 6.900 kPa (1.000 lb/pulg2) y a velocidad (rpm)
máxima de la bomba, use la fórmula de la tabla 5 para determinar el porcentaje de
pérdida de flujo.

Si el banco de pruebas no se puede operar a 6.900 kPa (1.000 lb/pulg2) o a velocidad

(rpm) máxima de la bomba, opere el eje de la bomba a 1.000 rpm. Mida el flujo de la
bomba a 690 kPa (100 lb/pulg2) y a 6.900 kPa (1.000 lb/pulg2). Use estos valores en la
parte superior de la fórmula indicada en la tabla 6. Para la parte inferior de la fórmula,
opere el eje de la bomba a 2.000 rpm. Mida el flujo de la bomba a 690 kPa (100
lb/pulg2).
 Tabla 6

   Flujo de la bomba a
           
690 kPa (100 lb/pulg2)    

Flujo de la bomba a
−  
6.900 kPa (1.000 lb/pulg2)    
Pérdida de flujo en
   Flujo de la bomba a ×     100     =    
porcentaje    
690 kPa (100 lb/pulg2) y a 2.000
rpm    
Pruebas y Ajustes
R1300G Load Haul Dump Hydraulic System

Número de medio -RENR6939- Fecha de publicación Fecha de actualización

03 -01/05/2007 -22/05/2007

   
i01857452

Relief Valve (Lift Circuit) - Test and Adjust

SMCS - 5117-036-LQ
Table 1

Required Tools    

Part Number     Part Description     Qty    

6C-7139     Manifold     1  

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.

Sudden movement or accidental starting of the machine can cause

personal injury or death to persons on or near the machine.

To prevent personal injury or death, perform the following:

Park the machine on a smooth, level surface.

Lower the work tool to the ground and engage the parking brake.

Stop the engine and remove the key.

Block the wheels and install the steering frame lock.

 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.

Note: The lift circuit relief valve should be connected to a hydraulic test bench to be
tested and adjusted correctly.

1. Release the pressure from the hydraulic system.

Reference: Refer to Systems Operation, Testing and Adjusting, "System

Pressure - Release" for the machine that is being serviced.

Ver imagen

Illustration 1 g00946841
Location of the lift circuit relief valve

(1) Lift circuit relief valve

2. Remove lift circuit relief valve (1) .

3. Install lift circuit relief valve (1) in the 6C-7139 Manifold. Connect the manifold
to a hydraulic test bench.

4. The pressure setting for lift circuit relief valve (1) is 31025 ± 345 kPa (4500 ±
50 psi).
 Ver imagen

Illustration 2 g00918074
Lift circuit relief valve

(2) Adjusting screw

(3) Locknut
5. If the pressure setting of lift circuit relief valve (1) is not correct, loosen locknut
(3). Turn adjusting screw (2) clockwise to increase the pressure. Turn adjusting
screw (2) counterclockwise to decrease the pressure.

6. When the pressure setting is correct, tighten locknut (3). Remove lift circuit
relief valve (1) from the 6C-7139 Manifold .

7. Install lift circuit relief valve (1) to the machine.

Pruebas y Ajustes
R1300G Load Haul Dump Hydraulic System

Número de medio -RENR6939- Fecha de publicación Fecha de actualización

03 -01/05/2007 -22/05/2007

   
i01856366

System Pressure - Release

SMCS - 5050-553-PX
Table 1

Required Tools    

Part Number     Part Description     Qty    

177-7861     Hose As     1  

6V-4143     Couplers     2  

8T-0860     Pressure Gauge     1  

Sudden movement of the machine or release of oil under pressure can

cause serious injury to persons on or near the machine.
To prevent possible injury, perform the procedure that follows before
testing and adjusting the hydraulic system.

Personal injury or death can result from escaping fluid under pressure.

Escaping fluid under pressure, even a very small pin-hole size leak, can
penetrate body tissue and cause serious injury and possible death. If
fluid is injected into your skin, it must be treated by a doctor familiar
with this type of injury.

Always use a board or cardboard when checking for a leak.

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.

Note: Permit only one operator on the machine. Keep all other personnel away from the
machine or in the operator's sight.
1. Move the machine to a smooth, horizontal location that is away from operating
machines and away from personnel.

2. Place the transmission direction and speed control in the NEUTRAL position
and in any speed position. Engage the steering and transmission lock lever.

3. Engage the parking brake. Place wheel blocks in front of the wheels and behind
the wheels.

4. When the work tool is raised for testing or for adjusting, make sure that the work
tool is supported correctly. Also, make sure that the work tool is fully in the
DUMP position. The lift circuit has high oil pressure when the lift arms raise the
front of the machine.

Note: Do not stop the machine with the front of the machine off the ground
unless this is required for a test. Lower the machine to the ground and stop the
engine.

5. If the machine is equipped with an optional ride control system, with the engine
running, press and hold the ride control switch to the SERVICE position. Move
the joystick control lever to the FLOAT position. This will relieve all of the
hydraulic pressure in the ride control accumulator.

6. Stop the engine.

7. Install the steering frame lock.

8. Move the joystick control lever through the full range of travel. This will relieve
any pressure that may be present in the implement hydraulic system.

9. Move the STIC steering control several times in both directions to release the
pressure in the steering system.

10. Release the braking system oil pressure.

Reference: Refer to Systems Operation, Testing and Adjusting, Braking

System, "System Pressure - Release" for the machine that is being serviced.

11. Depress the breaker relief valve on the hydraulic tank to release the pressure in
the hydraulic tank.
 Ver imagen

Illustration 1 g00946503
(1) Pressure tap (for the rod end of the tilt cylinder)

(2) Pressure tap (for the head end of the tilt cylinder)
12. Connect a 177-7861 Hose As and an 8T-0860 Pressure Gauge to pressure tap
(1). If there is any pressure on the gauge, move the joystick control lever to all
positions until all the pressure is removed from the system.

13. Connect a 177-7861 Hose As and an 8T-0860 Pressure Gauge to pressure tap
(2). If there is any pressure on the gauge, move the joystick control lever to all
positions until all the pressure is removed from the system.

14. The pressure in the hydraulic system has now been released. The lines, fittings
and components can be removed.

15. Remove the test equipment.

Manual de Operación y Mantenimiento

R1300G Máquinas de carga, acarreo y descarga

Número de medio -SSBU7329- Fecha de publicación Fecha de actualización

02 -01/08/2009 -28/08/2009

   
i01970510

Cambios de velocidad y de sentido de marcha

SMCS - 1000; 7000

Se pueden hacer cambios de dirección y de sentido de marcha a plena velocidad del

motor. No obstante, se recomienda decelerar y/o frenar al cambiar de sentido de marcha.
Esto aumentará la comodidad del operador y la vida útil de los componentes del tren de
fuerza.
 1. Disminuya la velocidad del motor soltando el pedal acelerador.

2. Pise el pedal del freno para disminuir la velocidad de la máquina. Si cambia de

AVANCE a RETROCESO o viceversa, pare la máquina completamente.

3. Cambie la transmisión a la velocidad o sentido de desplazamiento deseado.

4. Suelte el pedal del freno.

5. Aumente la velocidad del motor pisando el pedal acelerador

Manual de Operación y Mantenimiento

R1300G Máquinas de carga, acarreo y descarga

Número de medio -SSBU7329- Fecha de publicación Fecha de actualización

02 -01/08/2009 -28/08/2009

   
i02052000

Ubicación de los filtros y rejillas

SMCS - 1000; 1050; 3000; 4000; 4250; 4300; 5050; 7000

Ver imagen

Ilustración 1 g01005078
(1) Respiradero del eje delantero
(2) Rejilla del tubo de llenado de aceite del sistema hidráulico

(3) Filtros de aceite del sistema hidráulico

(4) Filtro del aire de retorno de la cabina

(5) Filtro del presurizador de la cabina

(6) Filtros de aire del motor

(7) Rejilla del tubo de llenado del tanque de combustible

(8) Filtro de aceite del motor

(9) Filtros del sistema de lubricación automática (si tiene)

(10) Respiradero del cárter del motor

(11) Respiradero del eje trasero

(12) Rejilla magnética de la transmisión

(13) Filtro de aceite de la transmisión

(14) Filtro primario de combustible

(15) Filtro secundario de combustible

Vvvvv

Manual de Operación y Mantenimiento

R1300G Máquinas de carga, acarreo y descarga

Número de medio -SSBU7329- Fecha de publicación Fecha de actualización

02 -01/08/2009 -28/08/2009

   
i03656308

Aceite del sistema hidráulico - Cambiar

SMCS - 5050-044

El aceite y los componentes calientes pueden causar lesiones personales.

No permita que aceite o componentes calientes toquen su piel.

ATENCION
Cerciórese de que se contengan los fluidos durante la inspección,
mantenimiento, pruebas, ajustes y reparación del producto. Esté
preparado para recoger el fluido en un recipiente adecuado antes de
 abrir un compartimiento o desarmar un componente que contenga
fluidos.

Para obtener información sobre las herramientas y suministros

necesarios para contener los fluidos de productos Caterpillar, consulte
la Publicación Especial, NENG2500, "Caterpillar Dealer Service Tool
Catalog".

Deseche todos los fluidos según los reglamentos y leyes locales.

Opere la máquina durante unos minutos para calentar el aceite del sistema hidráulico.

Estacione la máquina en terreno horizontal. Baje el cucharón hasta el suelo y aplique

una ligera presión hacia abajo. Conecte el freno de estacionamiento y pare el motor.

Ver imagen

Ilustración 1 g01003361
1. Alivie la presión del tanque hidráulico presionando la parte superior de la
válvula de alivio (1) antes de quitar la tapa de llenado de aceite.

Ver imagen
 Ilustración 2 g01796754
2. Quite lentamente la tapa de llenado de aceite (2) para aliviar la presión restante.

3. Quite el tapón de drenaje del tanque hidráulico (3). Drene el aceite en un

recipiente adecuado.

4. Limpie y coloque el tapón de drenaje.

5. Cambie los filtros de aceite del sistema hidráulico.

ReferenciaVea el procedimiento correcto en el Manual de Operación y

Mantenimiento, "Filtro de aceite del sistema hidráulico - Reemplazar".

6. Quite el colador del tubo de llenado del aceite hidráulico.

7. Lave la tapa del tubo de llenado de aceite y el colador en disolvente limpio no

inflamable. Deje que la tapa del tubo de llenado de aceite y el colador se sequen.

8. Inspeccione la empaquetadura de la tapa del tubo de llenado de aceite. Utilice

una empaquetadura nueva si la empaquetadura usada está dañada. Instale el
colador en el tubo de llenado.

9. Llene el tanque hidráulico con aceite limpio. Asegúrese de que el nivel del aceite
esté en la marca "FULL" (Lleno) de la mirilla indicadora. Instale la tapa del tubo
de llenado.

ReferenciaPara obtener información sobre lubricantes y capacidades de llenado,

consulte el Manual de Operación y Mantenimiento, "Viscosidades de lubricantes
y Capacidades de llenado".

10. Arranque el motor y hágalo funcionar a velocidad baja en vacío. Revise para
determinar si hay fugas.

Ver imagen
 Ilustración 3 g01796755
11. Mantenga el nivel del aceite por encima de la marca "ADD COLD" (Añadir
frío) en la mirilla (4). Añada más aceite, si es necesario, por el tubo de llenado
(5) .

Nota: El aceite no debe tener burbujas. La presencia de burbujas en el aceite

significa que hay entradas de aire en el sistema hidráulico. Inspeccione las
mangueras de succión del sistema hidráulico y las abrazaderas de las mangueras.

12. Pare el motor.

13. Si es necesario, apriete cualquier abrazadera o conexión floja. Reemplace todas

las mangueras dañadas.