Cat 320C Excavator Hydraulic System Testing & Adjusting Manual - PDF DOWNLOAD

CATERPILLAR

RENR3817-02 September 2001

320C Excavator Hydraulic System ANB1-Up (Machine) BCB1-Up (Machine) BDB1-Up (Machine) AMC1-Up (Machine) BBC1-Up (Machine) BDC1-Up (Machine) CCD1-Up (Machine) ALF1-Up (Machine) BEF1-Up (Machine) AKH1-Up (Machine) BER1-Up (Machine) BPR1-Up (Machine) BRX1-Up (Machine)

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death couid occur to you or to other persons.

The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

WARNING The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method or operating technique that is not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or repair procedures that you choose.

The information, specifications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.

WARNING When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

3 Hydraulic System Table of Contents

Table of Contents Testing and Adjusting Section Testing and Adjusting General Testing and Adjusting Information Visual Inspection Hydraulic System Pressure - Release Main Hydraulic Pump Air Pressure - Purge

4 4 4 7

Performance Tests Operational Checks 9 Engine Performance - Test (Engine Speed) 9 Travel on Level Ground - Test (Optional Test) 10 Travel on Level Ground - Test 11 Machine Drift on a Slope - Check 12 Swing Speed and Overswing on Level Ground Check 13 Swing Speed and Swing Drift on a Slope - Check ..14 Cylinder Drift - Check (Loaded Bucket) 15 Cylinder Drift - Check (Empty Bucket) 16 Cylinder Speed - Check 17 Hydraulic Pressure Adjustments Required Tools Relief Valve (Pilot) - Test and Adjust Relief Valve (Main) - Test and Adjust Relief Valve (Crossover) - Test and Adjust /0-^^ MM Relief Valve (Line) - Test and Adjust - ^ ^ Relief Valve (Swing) - Test and Adjust Solenoid Valve (Swing Parking Brake) - Test Control Valve (Boom Lowering) - Test and Adjust..

19 20 20 21 24 28 29 30

Pump Flow Measurement and Adjustment Main Pump (Flow) - Test (Constant Horsepower Flow Control) 34 Pump Control (Output Flow) - Adjust 40 Pump Control (Negative Flow) -Test 41 Pump Control (Negative Flow) - Adjust 48 Gear Pump (Pilot) - Test 49 Hydraulic Motor and Pump Performance Tests Swing Motor - Test (Measurement of Case Drain Oil) 53 Travel Motor - Test (Measurement of Case Drain Oil) 54 Reference Specifications Specifications

56

Index Section Index

60

4 Hydraulic System Testing and Adjusting Section

Testing and Adjusting Section

Visual Inspection SMCS Code: 5050-040

Testing and Adjusting General Testing and Adjusting information

A visual inspection of the system is the first step in order to troubleshoot a problem. Shut off the engine and lower all implements to the ground before performing the visual inspection.

1. Check the oil level in the hydraulic tank. Slowly loosen the fill/vent plug and release the pressure before the fill/vent plug is removed.

SMCS Code: 5050

WARNING Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted.

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.

When possible, the work tool must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and work tool have correct support.

2. Remove the hydraulic filter elements. Inspect the hydraulic filters for material that would give an indication of damage to a component.

The swing lock (if equipped) must be engaged before service is started.

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

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.

4. Inspect control linkages for bent components, broken components or damaged components.

The correct oil temperature, flow, and pressure are necessary for correct operation. Pump output (oil flow) is a function of engine speed (rpm) and valve adjustment. Oil pressure is caused by resistance to the flow of oil.

Visual checks and measurements are the first steps during troubleshooting. Refer to Testing And Adjusting, "Visual Inspection". Next, perform the operational checks. Refer to Testing And Adjusting, "Operational Checks". Finally, perform the required tests and adjustments on the machine.

i01246594

Hydraulic System Pressure Release SMCS Code: 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

5 Hydraulic System Testing and Adjusting Section • 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 WARNING Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

NOTICE 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.

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.

6 Hydraulic System Testing and Adjusting Section

Release Of Hydraulic Pressure From Multiple Hydraulic Circuits WARNING Personal injury can result from hydraulic oil pressure and hot oil.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

NOTICE 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.

1. Position the machine on level ground.

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.

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 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.

11. Shut off the engine.

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.

Illustration 2

7 Hydraulic System Testing and Adjusting Section 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.

Main Hydraulic Pump Air Pressure - Purge SMCS Code: 5070-542-AI When the main pumps have been serviced or the hydraulic oil has been replaced, remove the air from the hydraulic system. Remove the air from the hydraulic system in the following manner: NOTICE 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.

WARNING 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.

Illustration 3 Pump compartment (1) (2) (3) (4)

Connector O-Ring seal Case drain hose Negative flow control hose

1. While the engine is stopped, disconnect hose (3) from connector (1).

2. Remove connector (1) and O-Ring seal (2) from the pump housing.

3. Fill the main pumps with oil.

4. Inspect O-Ring seal (2). If the seal is damaged, replace the seal.

5. Install O-Ring seal (2) and connector (1) at the pump housing.

6. Connect hose (3) to connector (1). Tighten hose (3) to the specified torque.

NOTICE To avoid system damage, make sure that the hydraulic pump is properly filled with hydraulic oil before startup.

7. Start the engine.

8. Place the engine at low idle position. Raise the boom and hold the boom in this position.

9. Slowly loosen hose (4) until oil begins to flow around the hose connection.

10. Tighten hose (4) to the specified torque.

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

8 Hydraulic System Testing and Adjusting Section

Illustration 4 (5) Vent plug

12. Slowly loosen vent plug (5) until oil begins to flow from the opening.

13. Tighten the vent plug to the specified torque.

9 Hydraulic System Testing and Adjusting Section

Performance Tests

Table 2

320C L Machine Configuration

Operational Checks

Boom

Stick

Bucket

5.67 m (18 feet 6 inches)

2.92 m (9 feet 6 inches)

0.9 m3 (1.17 yd3)

SMCS Code: 5050-535 The operational checks can be used to find leakage in the system and components that are not functioning correctly. The speed of rod movement or the torque on a motor can be used to check the condition of the cylinders, motors and the pumps.

Engine Performance - Test (Engine Speed) SMCS Code: 1000-081

Perform the following operational checks in order to troubleshoot problems concerning the hydraulic circuits and components on the machine.

• Testing and Adjusting, "Engine Performance Test" • Testing and Adjusting, "Travel On Level Ground Test"

Table 3

Required Tools Part Number

Description

Qty

9U-7400

Multitach Tool Group

1

1. Position the machine on level ground.

• Testing and Adjusting, "Travel On Level Ground - Test (Optional Test)"

2. Stop the engine.

• Testing and Adjusting, "Machine Drift On A Slope - Check"

3. Install 9U-7400 Multitach Tool Group on the engine.

• Testing and Adjusting, "Swing Speed And Overswing On Level Ground - Check"

4. Start the engine.

• Testing and Adjusting, "Swing Speed And Swing Drift On A Slope - Check" • Testing and Adjusting, "Cylinder Drift - Check (Empty Bucket)" • Testing and Adjusting, "Cylinder Drift - Check (Loaded Bucket)" • Testing and Adjusting, "Cylinder Speed - Check" The specifications that are listed in tables for the operational checks are calculated average values.

The values will vary due to the configuration of the machine and engine speed. Table 1 and Table 2 contain the machine configurations that were used in order to obtain these specifications.

Reference: Refer to Testing and Adjusting, "Engine Performance - Test" for the specifications for engine speed.

Table 1

320C Machine Configuration Boom

Stick

Bucket

5.67 m (18 feet 6 inches)

2.92 m (9 feet 6 inches)

0.8 m3 (1.04 yd3)

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

6. Read the engine speed display (rpm) on the multitach. Refer to Table 4 for the specifications for engine speed at the desired engine operation.

10 Hydraulic System Testing and Adjusting Section Table 5

Table 4

Required Tools

Specifications Item New

Rebuild

1860 ± 5 0 rpm(1)

1660 to 1910 rpm(1)

1970 ± 5 0 rprnP)

1770 to 2020 rpm (3)

900 ± 50 rpm

900 ± 100 rpm

No load high idle(2)

No load low idle Maximum speed with load (4) No load speed(6)

Service Limit

1720 rpm(5)

1670 rpm(5)

1300 ± 80 rpm

Part Number

Description

Qty

Stopwatch

1

1620 rpm(5) 1300 ± 100 rpm

(1) AEC switch in the OFF position (2) Three seconds after the engine speed dial was placed at position "10" (3) Engine rpm within three seconds after the engine speed dial was placed at position "10" (4) Pressure is relieved from both pumps (stall condition).

(5) Minimum rpm (6) AEC switch in the ON position

Note: A New specification is the performance that can be expected for a new machine. A Rebuild specification is the performance that can be expected after rebuilding the components of a system. Performance beyond the Service Limit is an indication of these problems: improper maintenance or adjustment, component wear, and failure.

Travel on Level Ground - Test (Optional Test) SMCS Code: 4351-081 Note: When the procedure for the Travel Test On Level Ground cannot be performed, this test may be used as a substitute.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting "Specifications".

Illustration 5

1. Start the engine.

2. Position the machine on level ground.

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

4. Raise a track off the ground. Refer to Illustration 5.

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

6. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch OFF. 7. Place the travel speed control switch in HIGH position.

8. Move the travel lever of the raised track to full travel position.

9. Measure the time that is required for the raised track to make three complete revolutions.

Measure the time that is required in each direction.

10. Place the travel speed control switch in the LOW position and repeat Steps 8 through 9.

11 Hydraulic System Testing and Adjusting Section Table 6

320C Time For Three Revolutions (time in seconds) New

Rebuild

Service Limit

17.0 or less

18.0 or less

19.0 or less

27.5 or less

28.5 or less

30.5 or less

Travel Speed Forward HIGH Reverse LOW

Forward Reverse

Table 7

320C L Time For Three Revolutions (time in seconds)

HIGH

Forward Reverse

LOW

Forward Reverse

Illustration 6

New

Rebuild

Service Limit

(A) Preliminary run 5 m (16.4 ft)

18.5 or less

19.6 or less

20.7 or less

(C) Bucket height 0.5 to 1 m (1.6 to 3.3 ft)

30.0 or less

31.0 or less

33.2 or less

1. Travel distance must be at least 25 m (82 ft) long. Travel test ground must be hard and as level as possible.

Travel Speed

(B) Travel distance 20 m (65.6 ft)

2. Draw a 25 m (82 ft) straight line on travel test ground as a reference line.

Travel on Level Ground - Test SMCS Code: 4351-081 Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 8

3. Start the engine.

4. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch OFF. 5. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).

6. The bucket should be empty.

7. Position the machine so that one track is parallel with the reference line. Position the machine for the travel test. Refer to Illustration 6.

8. Place the travel speed control switch in HIGH position.

9. Move the machine by operating both travel levers at the same time.

Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

10. The first 5 m (16.4 ft) are for a preliminary run.

Measure the travel time that is required to travel the remaining 20 m (65.6 ft). Measure the time that is required in each direction.

11. Measure the travel deviation from the reference line.

12. Place the travel speed control switch on the LOW position and repeat Steps 9 through 11.

12 Hydraulic System Testing and Adjusting Section Table 11

Table 9 Travel Time (time in seconds) New

Rebuild

Service Limit

14.0 or less

15.0 or less

16.0 or less

22.0 or less

23.5 or less

25.0 or less

Travel Speed HIGH

Forward Reverse

LOW

Forward Reverse

Required Tools Part Number

Description

Qty

Stopwatch

1

Scale150 mm (6 inch)

1

Note: The following table represents the travel deviation (distance) from the reference line.

Table 10 Travel Deviation mm (inch) New

Rebuild

Service Limit

800 (31.5) or less

1200 (47.2) or less

1500 (59.1) or less

800 (31.5) or less

1200 (47.2) or less

1500 (59.1) or less

Travel Speed Forward HIGH Reverse Forward LOW Reverse

Illustration 7

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

2. Position the implements, as shown. Refer to Illustration 7.

Machine Drift on a Slope Check

3. The bucket should be empty.

SMCS Code: 4095-535 Measuring the amount of drift of the machine on a slope will determine if there is a need to check the travel brake.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Illustration 8

4. To indicate the machine's relative position to the slope, put a mark on both the track and the track roller frame. Refer to Illustration 8.

5. Stop the engine.

6. Measure the machine movement on the slope after three minutes.

13 Hydraulic System Testing and Adjusting Section Table 12

Drift mm (inch) New

Rebuild

Service Limit

0

0

0

Swing Speed and Overswing on Level Ground - Check SMCS Code: 5058-535-ZW Measuring the swing speed and the overswing of the machine will determine if there is a need to check the swing motor or the anti-reaction valve.

The fine swing control switch (if equipped) must be in the OFF position.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 13

Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

Illustration 9

1. Position the machine on level ground. Refer to Illustration 9.

2. Stop the engine.

Illustration 10 (A) Upper frame (B) Undercarriage frame (C) Marking

3. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer race of the swing bearing. The mark will be used as a target to stop the swing operation. Refer to Illustration 10.

4. The bucket should be empty.

5. Move the swing joystick in either direction until the machine completes a 180 degree swing operation away from the target.

6. Move the swing joystick in either direction until the machine completes a 180 degree swing operation toward the target. Return the swing joystick to the NEUTRAL position at the target.

7. Measure the amount of overswing by measuring the distance between the marks on the swing bearing. Refer to Illustration 10.

Note: Use a point that is visible from the operator seat as a reference point for the target.

14 Hydraulic System Testing and Adjusting Section Table 14 Overswing Item

New

Rebuild

Service Limit

Right Swing

1100 mm (43.3 inch) or less

1200 mm (47.2 inch) or less

1400 mm (55.1 inch) or less

Left Swing

8. Move the swing joystick in each direction and measure the time that is required to complete a 180 degree swing operation.

Table 15 Illustration 11

Swing Time Item

New

Rebuild

Service Limit

Right Swing

4.2 seconds or less

4.6 seconds or less

5.2 seconds or less

Left Swing

g00298078

1. Complete the following steps in order to measure the swing speed on a slope. a. The bucket should be empty. b. Position the machine on a slope of 12 degrees. Refer to Illustration 11.

i01586858

Swing Speed and Swing Drift on a Slope - Check

c. Position the implements at maximum reach and close the bucket. Position the bucket above the ground so that the bucket will not come in contact with any obstacles.

SMCS Code: 5058-535-ZW Measuring the swing speed on a slope will determine if there is a need to check the swing motor and the anti-reaction valve. Measuring the swing drift on a slope will determine if there is a need to check the swing parking brake.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Illustration 12

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

g00298079

d. Position the upper structure at position (A). The upper structure should be at a 90 degree angle to the lower structure. Refer to Illustration 12.

Table 16

Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

e. Measure the time that is required to swing the upper structure from position (A) to position (B). f. Position the upper structure at position (C).

The upper structure should be at a 90 degree angle to the lower structure.

15 Hydraulic System Testing and Adjusting Section g. Measure the time that is required to swing the upper structure from position (C) to position (B).

e. Start the engine.

Table 17

Swing Time (seconds) Item Right Swing

d. Leave the machine in this position for three minutes. Measure the swing drift on the circumference of the swing bearing.

New

Rebuild

Service Limit

5.2 or less

5.7 or less

6.5 or less

Left Swing 2. Complete the following steps in order to measure the swing drift on a slope.

f. Position the upper structure at position (C). The upper structure should be at a 90 degree angle to the lower structure. Refer to Illustration 13. g. Repeat Steps 2.b through 2.d.

Table 18

Swing Drift mm (inch) Item Right Swing

New

Rebuild

Service Limit

0

0

0

Left Swing

Cylinder Drift - Check (Loaded Bucket) SMCS Code: 7562-535-D9 Illustration 13

a. Position the upper structure at position (A). The upper structure should be at a 90 degree angle to the lower structure. Refer to Illustration 13.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Illustration 14 (A) Upper frame (B) Undercarriage frame (C) Marking

b. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer race of the swing bearing. Refer to Illustration 14. c. Stop the engine.

16 Hydraulic System Testing and Adjusting Section Table 20

Table 19 Required Tools

Cylinder Drift (Loaded Bucket)

Part Number

Description

Qty

New Boom Cylinder

New Stick Cylinder

New Bucket Cylinder

5P-3277

Measuring Tape

1

Stopwatch

1

6.0 mm (0.24 inch) or less

12.0 mm (0.47 inch) or less

18.0 mm (0.71 inch) or less

i01572461

Cylinder Drift - Check (Empty Bucket) SMCS Code: 7562-535-D9 Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Illustration 15

1. Position the machine on level ground. Refer to Illustration 15.

2. Load the bucket.

Weight of bucket load 320C 320C L

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

Table 21

1050 kg (2310 lb) 1200 kg (2650 lb)

3. Raise the boom until the top stick pin is the same height as the boom foot pin.

Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

4. Fully extend the bucket cylinder.

5. Fully retract the stick cylinder.

6. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.

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

8. Stop the engine.

9. Leave the machine in this position for three minutes. Measure each cylinder's length from cylinder pin to cylinder pin for drift.

Illustration 16

1. Position the machine on level ground. Refer to Illustration 16.

2. Empty the bucket.

17 Hydraulic System Testing and Adjusting Section 3. Raise the boom until the top stick pin is the same height as the boom foot pin.

4. Fully extend the bucket cylinder.

5. Fully retract the stick cylinder.

6. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.

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

8. Stop the engine.

9. Leave the machine in this position for five minutes. Measure each cylinder's length from cylinder pin to cylinder pin for drift.

Table 22

Illustration 17 (A) Extension test (B) Retraction test

a. Place the machine on level ground.

Cylinder Drift (Empty Bucket) Item

New

Rebuild

Service Limit

Boom Cylinder

6.0 mm (0.24 inch) or less

12.0 mm (0.47 inch) or less

24.0 mm (0.94 inch) or less

Stick Cylinder

10.0 mm (0.39 inch) or less

15.0 mm (0.59 inch) or less

25.0 mm ( 0.98 inch) or less

Bucket Cylinder

10.0 mm ( 0.39 inch) or less

15.0 mm (0.59 inch) or less

25.0 mm ( 0.98 inch) or less

b. The bucket should be empty. c. Fully retract the bucket cylinder and the stick cylinder. d. Position the bucket on the ground. With a stopwatch, measure the time that is required to fully extend the boom cylinders. e. Position the boom cylinders at full extension.

With a stopwatch, measure the time that is required for the bucket to come in contact with the ground. f. Refer to the specifications in Table 23 for the operating speed of the boom cylinders.

Cylinder Speed - Check SMCS Code: 5456-535-VF; 5458-535-VF

2. Perform the following steps in order to test the operating speed of the stick cylinder.

Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this test. Refer to Testing and Adjusting, "Engine Performance - Test" for the engine speed that was used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were used for this test.

Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing this operational check. Refer to Testing and Adjusting, "Specifications".

1. Perform the following steps in order to test the operating speed of the boom cylinders.

Illustration 18 (A) Extension test (B) Retraction test

a. Place the machine on level ground. b. The bucket should be empty.

18 Hydraulic System Testing and Adjusting Section c. Position the upper surface of the boom parallel to the ground.

Table 23 Cylinder Operating Speed (seconds)

d. Fully extend the bucket cylinder. e. Retract the stick cylinder. With a stopwatch, measure the time that is required to fully extend the stick cylinder. f. Extend the stick cylinder. With a stopwatch, measure the time that is required to fully retract the stick cylinder. g. Refer to the specifications in Table 23 for the operating speed of the stick cylinder.

3. Perform the following steps in order to test the operating speed of the bucket cylinder.

Illustration 19 (A) Extension test (B) Retraction test

a. Place the machine on level ground. b. The bucket should be empty. c. Position the upper surface of the boom parallel to the ground. d. Position the stick so that the stick is perpendicular to the ground. e. Fully retract the bucket cylinder. f. With a stopwatch, measure the time that is required to fully extend the bucket cylinder. g. Position the bucket cylinder at full extension.

With a stopwatch, measure the time that is required to fully retract the bucket cylinder. h. Refer to the specifications in Table 23 for the operating speed of the bucket cylinder.

New

Rebuild

Service Limit

Extension

2.8 ± 0.5

3.2(1)

3.6(1)

Retraction

1.9 ±0.5

2.2(1)

2.4 (1)

Extension

3.2 ± 0.5

3.7(1)

4.2 (1)

Retraction

2.4 ± 0.5

2.6(1)

3.0(1)

Extension

3.3 ± 0.5

3.8(1)

4.3 (1)

Retraction

1.8 ±0.5

2.1(1)

2.3(1)

Item Boom

Stick

Bucket (1) (1) M a x i m u m

Maximum

19 Hydraulic System Testing and Adjusting Section

Hydraulic Pressure Adjustments

(Table 24, contd)

Required Tools Part Number

Required Tools

Description

Qty

6K-6307

O-Ring Seal

18

7M-8485

O-Ring Seal

8

SMCS Code: 0701; 0738; 0770; 0774; 0775; 0784; 7320

1P-3703

Rectangular Seal

2

5P-0201

Hose

4

S/N: ANB1-Up

5P-1010

Sleeve

8

S/N: BCB1-Up

5P-3277

Measuring Tape

1

8T-0470

Thermometer Group

1

8T-0855

Pressure Gauge

2

8T-0856

Pressure Gauge

2

S/N: BDB1-Up S/N: AMC1-Up S/N: BBC1-Up

8T-0861

Pressure Gauge

3

S/N: BDC1-Up

8T-4184

Bolt

8

S/N: ALF1-Up

8T-4223

Hard Washer

8

S/N: BEF1-Up

8T-5082

Union

1

S/N: AKH1-Up

8T-8902

Elbow

4

S/N: BER1-Up

1U-8292

Adapter

2

1U-8303

Fitting

2

9U-7335

Blocking Cover

2

9U-7400

Multitach Tool Group

1

6V-0400

Half Flange

4

177-7860

Hose

5

6V-3965

Nipple Assembly

2

6V-3989

Unvalved Nipple

5

6V-4143

Coupler Assembly

10

6V-8397

O-Ring Seal

8

6V-8398

O-Ring Seal

4

6V-8716

Seal Connector

2

6V-9508

Face Seal Plug

2

6V-9509

Face Seal Plug

1

6V-9829

Cap

2

6V-9830

Cap

1

6V-9832

Cap

4

6V-9840

Swivel Tee

2

6V-9854

Swivel Elbow

2

S/N: BPR1-Up S/N: BRX1-Up Table 24 Required Tools Part Number

Description

Qty

Container for measuring

1

Remote drain hose with inside diameter of 20 mm (0.78 inch)

1

Scale 150 mm (6 inch)

1

Stopwatch

1

FT-2542

Track block assembly

1

4C-6481

Coupler Assembly

8

4C-6482

Nipple Assembly

8

4C-8767

Coupling

8

4C-9910

Portable Hydraulic Tester (Flow Meter)

2

8C-9026

Adapter

4

4I-6140

Coupling

1

4I-6141

Coupling

2

3J-1907

O-Ring Seal

4

5K-9090

O-Ring Seal

16 (continued)

20 Hydraulic System Testing and Adjusting Section

Relief Valve (Pilot) - Test and Adjust SMCS Code: 5072-025; 5072-081 1. Place the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

11. Turn setscrew (29) until the pressure gauge reading at pressure tap (30) is 4100 ± 200 kPa • (595 ± 29 psi).

Note: Turning setscrew (29) clockwise increases the pressure. Turning setscrew (29) counterclockwise decreases the pressure.

Note: Always make final pressure adjustments on pressure rise.

12. Tighten locknut (28) to a torque of 49 (36 ± 4 lb ft).

4.9 N-m

Note: Normal operation of the engine and pumps are necessary for the pressure adjustment. If the results of the pressure adjustments are not correct, then the engine and the pump characteristic curve needs to be checked.

Relief Valve (Main) - Test and Adjust SMCS Code: 5069-025; 5069-081

Illustration 20 Pilot oil manifold compartment (28) (29) (30) (31)

Locknut Setscrew Pressure tap Pilot filter

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

2. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

4. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (30).

5. Start the engine.

6. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.

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

8. Check the pilot relief valve setting at pressure tap (30).

9. The pilot relief valve setting should be 4100 ± 200 kPa (595 ± 29 psi). If the pilot relief valve setting is not within the specification, adjust the pilot relief valve.

10. In order to adjust the pilot relief valve, loosen locknut (28).

Illustration 21 Pump compartment (1) Pressure tap (right pump delivery pressure) (2) Pressure tap (left pump delivery pressure) (3) Pressure tap (power shift pressure)

3. Attach a 60000 kPa (8700 psi) pressure gauge to pressure tap (1).

4. Start the engine.

>

21 Hydraulic System Testing and Adjusting Section 5. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.

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

1. The main relief valve pressure setting should be 34300 ± 490 kPa (4950 ± 72 psi). If the main relief valve is not within the specification, adjust the main relief valve pressure setting to the correct pressure specification before performing Step 2. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".

7. Open the bucket until the bucket cylinder rod is at the full retraction.

8. Check the main relief valve pressure setting at pressure tap (1).

9. Return the joystick for the bucket to the NEUTRAL position.

10. The main relief valve pressure setting should be 34300 ± 490 kPa (4950 ± 72 psi). If the main relief valve pressure setting is not within the specification, adjust the main relief valve pressure setting.

Top of main control valve (4) Adjustment screw (5) Locknut (6) Main relief valve

2. Loosen locknut (5) and turn adjustment screw (4) clockwise for one half turn. Tighten locknut (5) to the specified torque.

Note: Always make final pressure adjustments on pressure rise.

(4) Adjustment screw (5) Locknut (6) Main relief valve

Relief Valve (Crossover) - Test and Adjust SMCS Code: 5069-036

11. In order to adjust the main relief valve, loosen locknut (5) and turn adjustment screw (4) until the pressure gauge reading at pressure tap (1) is 34300 ± 490 kPa (4950 ± 72 psi).

Note: Turning adjustment screw (4) clockwise increases the pressure. Turning adjustment screw (4) counterclockwise decreases the pressure.

Note: A temporary setting of the main relief valve is required before travel crossover relief valves can be tested. Refer to Testing And Adjusting, "Relief Valve (Main) - Test and Adjust".

1. Position the machine on level ground.

2. Stop the engine.

Note: Always make final pressure adjustments on pressure rise.

12.Tighten locknut (5) to a torque of 50 ± 10 N.m (37 ± 7 lb ft).

Temporary Setting of the Main Relief Valve Note: A temporary setting of the main relief valve is required before any line relief valve can be adjusted.

22 Hydraulic System Testing and Adjusting Section 8. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing And Adjusting, "Engine Performance - Test" for engine rpm settings.

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

Pump compartment (1) Pressure tap (right pump delivery pressure) (2) Pressure tap (left pump delivery pressure) (3) Pressure tap (power shift pressure)

3. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (3).

4. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (1). Use this pressure gauge to monitor the crossover relief valve pressure setting of the right travel motor.

5. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (2). Use this pressure gauge to monitor the crossover relief valve pressure setting of the left travel motor.

Illustration 26 Monitor (A) Message display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key (G) Cancel key (H) Set key (I) OK key (J) Menu key

Illustration 25

10. Start Service Mode and input a fixed power shift pressure of 2900 kPa (420 psi).

Sprocket (left track) (16) Sprocket (17) FT-2547 Track block assembly

6. Place track block assembly (17) in sprocket (16) in order to block forward left travel. Refer to Illustration 25.

7. Start the engine.

a. Press menu key (J).

Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu mode will be cancelled and the previous display will be restored to message display (A). b. Press down key (E) in order to highlight the menu item "SERVICE OPTIONS" on the message display. Press OK key (I).

23 Hydraulic System Testing and Adjusting Section c. Input the password "FFF2". Press left key (D) or right key (F) in order to change the position of the flashing character. Press up key (C) or press down key (E) in order to change the value of the flashing character. Press OK key (I) after the correct password is displayed. d. Press down key (E) once in order to highlight the second line on the message display. e. Press right key (F) repeatedly until "DEVICE TEST" appears on the message display. f. Press down key (E) in order to move down one line on the message display. g. Press right key (F) until the "PS PRV - FIXED" appears on the message display. h. Press down key (E). i. Press OK key (I). The display on line 4 of the message display will now change to a numeric value. These characters represent the power shift pressure (kPa). j. Press left key (D) or right key (F) in order to increase or decrease the numeric value that is displayed on line 4 of the message display.

Pressing left key (D) one time decreases the power shift pressure 10 kPa (1.5 psi).

Pressing right key (F) one time increases the power shift pressure 10 kPa (1.5 psi).

Note: The value for power shift pressure on the monitor may not always match the pressure reading on the pressure gauge. Adjust the value on the monitor until the desired power shift pressure is attained on the pressure gauge that is connected to the pressure tap for power shift pressure. The actual power shift pressure must be 2900 kPa (420 psi) on the pressure gauge. k. Press up key (C). "SUCCESS" should appear on the message display.

Note: To prevent a change in power shift pressure during the relief valve adjustment, do not turn the engine start switch to the OFF position.

Note: Refer to Service Manual, "Engine And Pump Electronic Control System' for additional information on Service Mode.

Illustration 27 Travel brake valve (left side) (18) (19) (20) (21) (22) (23)

Locknut Adjustment screw Crossover relief valve (forward left travel) Crossover relief valve (reverse left travel) Locknut Adjustment screw

11. Slowly move the left travel control lever to full FORWARD position and check the pressure gauge reading at pressure tap (2). The pressure setting of crossover relief valve (20) should be 36800 ± 1470 kPa (5350 ±215 psi).

12. Return the left travel control lever to the NEUTRAL position.

13. In order to adjust crossover relief valve (20), loosen locknut (18) and turn adjustment screw (19) until the pressure gauge reading at pressure tap (2) is 36800 ± 1470 kPa (5350 ± 215 psi).

Note: Turning adjustment screw (19) clockwise increases the pressure. Turning adjustment screw (19) counterclockwise decreases the pressure.

Note: Always make final pressure adjustment on pressure rise.

14. Tighten locknut (18) to a torque of 130 ± 13 N-m (95 ± 10 lb ft).

Note: Always make final pressure adjustments on pressure rise.

15. Place track block assembly (17) in sprocket (16) in order to block reverse left travel.

16. Slowly move the left travel lever to full REVEF5SE position and check the pressure gauge reading at pressure tap (2). The pressure setting of crossover relief valve (21) should be 36800 ± 1470 kPa (5350 ± 2 1 5 psi).

17.Re*um the left travel control lever to Hie NEUTRAL position.

24 Hydraulic System Testing and Adjusting Section 18. In order to adjust crossover relief valve (21), loosen locknut (22) and turn adjustment screw (23) until the pressure gauge reading at pressure tap (2) is 36800 ± 1470 kPa (5350 ±215 psi).

Note: Turning adjustment screw (23) clockwise increases the pressure. Turning adjustment screw (23) counterclockwise decreases the pressure.

Note: Always make final pressure adjustment on pressure rise.

19.Tighten locknut (22) to a torque of 130 ± 13 N.m (95 ± 10 lb ft).

Illustration 28

Note: Always make final pressure adjustments on pressure rise.

Pump compartment

20. After relief valve adjustments, cancel Service Mode.

(1) Pressure tap (right pump delivery pressure) (2) Pressure tap (left pump delivery pressure) (3) Pressure tap (power shift pressure)

2 1 . Return the main relief valve pressure to the specified setting after crossover relief valve pressure setting is attained.

In order to adjust the crossover relief valves on the right travel motor, place stopper (17) in the sprocket for right travel. Use the pressure gauge at pressure tap (1) in order to monitor the crossover relief valve pressure settings for the right travel motor. Adjust the crossover relief valves on the right travel motor in the same manner as the adjustment for the left travel motor.

Relief Valve (Line) - Test and Adjust SMCS Code: 5117-025-L9; 5117-081-L9 Note: Adjustment procedures must be performed before a test and adjustment of any line relief valve pressure setting is attempted. A temporary setting of the main relief valve pressure is required before any line relief valve pressure setting is adjusted.

Refer to the adjustment procedures in Testing And Adjusting, "Relief Valve (Main) - Test and Adjust".

Test 1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

4. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (1).

5. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (2).

6. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (3). This is used to monitor power shift pressure.

7. Start the engine.

8. Place the machine controls at the following settings: engine speed dial 10 and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.

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

25 Hydraulic System Testing and Adjusting Section e. Press right key (F) repeatedly until "DEVICE TEST" appears on the message display. f. Press down key (E) in order to move down one line on the message display. g. Press right key (F) until the "PS PRV - FIXED" appears on the message display. h. Press down key (E). i. Press OK key (I). The display on line 4 of the message display will now change to a numeric value. These characters represent the power shift pressure (kPa). j. Press left key (D) or right key (F) in order to increase or decrease the numeric value that is displayed on line 4 of the message display.

Pressing left key (D) one time decreases the power shift pressure 10 kPa (1.5 psi).

Pressing right key (F) one time increases the power shift pressure 10 kPa (1.5 psi).

Illustration 29 Monitor (A) Message display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key (G) Cancel key (H) Set key (I) OK key (J) Menu key

10. Start Service Mode and input a fixed power shift pressure of 2900 kPa (420 psi). a. Press menu key (J).

Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu mode AIII be cancelled and the previous display will be restored to message display (A). b. Press down key (E) in order to highlight the menu item "SERVICE OPTIONS" on the message display. Press OK key (I). c. Input the password "FFF2". Press left key (D) or right key (F) in order to change the position of the flashing character. Press up key (C) or press down key (E) in order to change the value of the flashing character. Press OK key (I) after the correct password is displayed. d. Press down key (E) once in order to highlight the second line on the message display.

Note: The value for power shift pressure on the monitor may not always match the pressure reading on the pressure gauge. Adjust the value on the monitor until the desired power shift pressure is attained on the pressure gauge that is connected to the pressure tap for power shift pressure. The actual power shift pressure must be 2900 kPa (420 psi) on the pressure gauge. k. Press up key (C). "SUCCESS" should appear on the message display.

Note: To prevent a change in power shift pressure during the relief valve adjustment, do not turn the engine start switch to the OFF position.

Note: Refer to Service Manual, "Engine And Pump Electronic Control System" for additional information on Service Mode.

11. The pressure setting for both the head end and the rod end for each cylinder is 36800 ± 1470 kPa (5350 ± 215 psi).

26 Hydraulic System Testing and Adjusting Section

Illustration 30

Illustration 32

Main control valves (front view)

Main control valve (bottom view)

(7) Line relief valve (boom cylinder rod end) (8) Line relief valve (bucket cylinder head end) (9) Line relief valve (stick cylinder head end)

(12) Line relief valve (stick cylinder rod end) (13) Stick drift reduction valve

The following line relief valves are located on top of the main control valves: boom cylinder rod end, bucket cylinder head end, and stick cylinder head end. The line relief valve for the bucket cylinder rod end is located under the main control valves and opposite the line relief valve for bucket cylinder head end (8).

The line relief valve (stick cylinder head end) (12) is located on stick drift reduction valve (13).

Illustration 33 Line relief valve (typical example) (14) Locknut (15) Adjustment screw Illustration 31 Main control valve (bottom view) (10) Boom drift reduction valve (11) Line relief valve (boom cylinder head end)

The line relief valve (boom cylinder head end) (11) is located on boom drift reduction valve (10).

Note: After relief valve adjustments, cancel Service Mode.

Note: Return the main relief valve pressure to the specified setting after testing and adjusting any line relief valve. Refer to Testing And Adjusting, "Relief Valve (Main) - Test and Adjust" for the main relief valve pressure setting.

Adjustment (Stick Cylinder) 1. To adjust the line relief valve pressure setting of the stick cylinder rod end, move the joystick for the stick until the stick is at the full STICK OUT position (full retraction of stick cylinder). Hold the joystick for the stick in this position.

27 Hydraulic System Testing and Adjusting Section 2. Check the pressure in the stick cylinder rod end on the pressure gauge at pressure tap (2).

3. Return the joystick for the stick to the NEUTRAL position.

4. Loosen locknut (14) on the stick line relief valve. Turn adjustment screw (15) until the pressure gauge reading at pressure tap (2) is 36800 ± 1470 kPa (5350 ±215 psi).

5. To adjust the line relief valve pressure setting of the bucket cylinder rod end, move the joystick for the bucket until the bucket is at the full BUCKET OPEN position (full retraction of bucket cylinder).

Hold the joystick for the bucket in this position.

6. Check the pressure in the bucket cylinder rod end on the pressure gauge at pressure tap (1).

7. Return the joystick for the bucket to the NEUTRAL position.

5. To adjust the line relief valve pressure setting of the stick cylinder head end, move the joystick for the stick until the stick is at the full STICK IN position (full extension of stick cylinder). Hold the joystick for the stick in this position.

8. Loosen locknut (14) on the bucket line relief valve. Turn adjustment screw (15) until the pressure gauge reading at pressure tap (1) is 36800 ± 1470 kPa (5350 ±215 psi).

6. Check the pressure in the stick cylinder head end on the pressure gauge at pressure tap (2).

9. After completion of line relief valve adjustment, tighten locknut (14).

7. Return the joystick for the stick to the NEUTRAL position.

Note: Turning adjustment screw (15) clockwise increases the pressure. Turning adjustment screw (15) counterclockwise decreases the pressure.

8. Loosen locknut (14) on the stick line relief valve. Turn adjustment screw (15) until the pressure gauge reading at pressure tap (2) is 36800 ± 1470 kPa (5350 ± 215 psi).

9. After completion of line relief valve adjustment, tighten locknut (14).

Note: Turning adjustment screw (15) clockwise increases the pressure. Turning adjustment screw (15) counterclockwise decreases the pressure.

Note: Always make final pressure adjustment on pressure rise.

Adjustment (Boom Cylinders) 1. To adjust the line relief valve pressure setting of the boom cylinder head end, move the joystick for the boom until the boom is at the full BOOM RAISE position (full extension of boom cylinders).

Hold the joystick for the boom in this position.

Note: Always make final pressure adjustment on pressure rise.

2. Check the pressure in the boom cylinder head end on the pressure gauge at pressure tap (1).

Adjustment (Bucket Cylinder)

3. Return the joystick for the boom to the NEUTRAL position.

1. To adjust the line relief valve pressure setting of the bucket cylinder head end, move the joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full extension of bucket cylinder). Hold the joystick for the bucket in this position.

4. Loosen locknut (14) on the boom line relief valve. Turn adjustment screw (15) until the pressure gauge reading at pressure tap (1) is 36800 ± 1470 kPa (5350 ± 215 psi).

2. Check the pressure in the bucket cylinder head end on the pressure gauge at pressure tap (1).

Note: In order to adjust the line relief valve pressure setting for the boom cylinder rod end, a temporary adjustment of the line relief valve for the bucket cylinder rod end must be performed.

3. Return the joystick for the bucket to the NEUTRAL position.

4. Loosen locknut (14) on the bucket line relief valve. Turn adjustment screw (15) until the pressure gauge reading at pressure tap (1) is 36800 ± 1470 kPa (5350 ±215 psi).

5. Loosen locknut (14) on the line relief valve for the BUCKET OPEN function. Turn adjustment screw (15) by one half turn in a clockwise direction.

Tighten locknut (14) on the line relief valve for the bucket cylinder.

28 Hydraulic System Testing and Adjusting Section 6. Move the joystick for the bucket until the bucket is at the full BUCKET OPEN position (full retraction of the bucket cylinder). Hold the joystick for the bucket in this position. At the same time, move the joystick for the boom until the boom is at the full BOOM DOWN position (full retraction of boom cylinders). Hold the joystick for the boom in this position.

7. Check the pressure in the boom cylinder rod end on the pressure gauge at pressure tap (1).

8. Return the joystick for the boom to the NEUTRAL position.

9. Loosen locknut (14) on the boom line relief valve. Turn adjustment screw (15) until the pressure gauge reading at pressure tap (1) is 36800 ± 1470 kPa (5350 ±215 psi).

10. Tighten locknut (14) on the boom line relief valve.

Note: Turning adjustment screw (15) clockwise increases the pressure. Turning adjustment screw (15) counterclockwise decreases the pressure.

Illustration 34

900666193

Pump compartment (1) Pressure tap (right pump delivery pressure) (2) Pressure tap (left pump delivery pressure) (3) Pressure tap (power shift pressure)

4. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (2).

Note: Always make final pressure adjustment on pressure rise.

11. After completion of line relief valve adjustment for the boom cylinders, return the line relief valve pressure setting of the bucket to the specified pressure setting.

Note: If an appropriate location is not available to fully extend the boom cylinders, exchange the functions of the boom line relief valves. Remove the line relief valve for the boom cylinder head end and the line relief valve for the boom cylinder rod end from the main control valve. Exchange the location in the main relief valve of the line relief valves.

Adjust the pressure of the boom line relief valve that is now attached in the head end. After completion of line relief valve adjustment, return the respective line relief valves to the original locations.

Illustration 35

900668854

Pilot oil manifold (28) Connector (29) Swing parking brake solenoid valve

5. Disconnect connector (28) from swing parking brake solenoid valve (29).

6. Start the engine.

i01586888

Relief Valve (Swing) - Test and Adjust SMCS Code: 5454-036 1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

7. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Reference: Refer to Testing And Adjusting, "Engine Performance - Test" for engine rpm settings.

8. Move the swing joystick slowly and ensure that the swing parking brake is operating properly.

29 Hydraulic System Testing and Adjusting Section 17. In order to adjust the swing relief valve, loosen locknut (27). Turn adjustment plug (26) until the pressure gauge reading at pressure tap (2) is 26000 ± 980 kPa (3750 ± 140 psi).

Note: Turning adjustment plug (26) clockwise increases the pressure. Turning adjustment plug (26) counterclockwise decreases the pressure.

Note: Always make final pressure adjustments on pressure rise.

18.Tighten locknut (27) to a torque of 117 ± 10 N-m (85 ± 7 lb ft).

Illustration 36 Swing motor (22) (23) (24) (25) (26) (27)

Adjustment plug Locknut Relief valve (left swing) Relief valve (right swing) Adjustment plug Locknut

9. Slowly move the swing joystick for a full SWING RIGHT operation and check the pressure for relief valve (25) at pressure tap (2).

10. Return the swing joystick to the NEUTRAL position.

11. The pressure setting of the swing relief valve is 26000 ± 980 kPa (3750 ± 140 psi). If the pressure reading at pressure tap (2) is not within the specification, adjust the swing relief valve.

12. In order to adjust the swing relief valve, loosen locknut (23). Turn adjustment plug (22) until the pressure gauge reading at pressure tap (2) is 26000 ± 980 kPa (3750 ± 140 psi).

Note: Turning adjustment plug (22) clockwise increases the pressure. Turning adjustment plug (22) counterclockwise decreases the pressure.

19. After completing the test and/or the adjustment procedures for the swing relief valves, stop the engine.

20. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

21. Connect connector (28) to the solenoid valve for swing parking brake (29).

101586890

Solenoid Valve (Swing Parking Brake) - Test SMCS Code: 5483-081-OD 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.

Note: Always make final pressure adjustments on pressure rise.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

13. Tighten locknut (23) to a torque of 117 ± 10 N-m (85 ± 7 lb ft).

Dispose of all fluids according to local regulations and mandates.

14. Slowly move the swing joystick for a full SWING LEFT operation and check the pressure for relief valve (24) at pressure tap (2).

15. Return the swing joystick to the NEUTRAL position.

16. The pressure setting of the swing relief valve is 26000 ± 980 kPa (3750 ± 140 psi). If the pressure reading at pressure tap (2) is not within the specification, adjust the swing relief valve.

1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

30 Hydraulic System Testing and Adjusting Section 12. Place the hydraulic activation control lever in the UNLOCKED position.

13. Check the pressure gauge reading at pressure gauge (1). When all of the joysticks are in the NEUTRAL position, the swing parking brake solenoid valve is not energized and the swing parking brake is engaged. The pressure gauge reading should be 0.0 kPa (0.0 psi).

14. Slowly move the swing joystick away from the NEUTRAL position and check the pressure on pressure gauge (1). The swing parking brake solenoid valve should now be energized and the swing parking brake should be released. The pressure gauge reading should be equal to the pilot system pressure.

Control Valve (Boom Lowering) - Test and Adjust SMCS Code: 5147-025-BM; 5147-081-BM Two preliminary temporary adjustment procedures must be performed: Illustration 37 (1) 8T-0856 Pressure Gauge (2) 6V-3989 Fitting (3) 6V-4143 Coupler (4) 177-7860 Hose Assembly (5) Swing motor (6) Connector at rear of swing motor (7)6V-8397 0-RingSeal (8) 6V-3965 Fitting Assembly (9) 3J -1907 O-Fting Seal (10) Pilot hose (11) 8T-8902 Tee

4. Disconnect pilot hose (10) from connector (6) at the rear of swing motor (5).

5. Install seal (7) and tee (11) to connector (6).

6. Install seal (7) and pilot hose (10) to tee (11).

7. Install seal (9) and fitting (8) to tee (11).

8. Assemble and install the test hose and gauge to fitting (8).

9. Start the engine.

10. Place the machine controls at the following settings : engine speed dial "10" and AEC switch OFF. Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.

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

1. A temporary setting of the main relief valve pressure is required.

2. A temporary line relief setting of the head end of the boom cylinder is required.

Four relief valves are involved in this procedure: • main relief valve • head end of the boom line relief valve • boom lowering control valve of the right cylinder • boom lowering control valve of the left cylinder 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.

31 Hydraulic System Testing and Adjusting Section Table 25

Specifications Relief Valve

(A) Main relief valve (B) Boom cylinder line (head end) (C) Boom lowering control valve

Torque for Locknut

New

Rebuild

Service Limit

34300 ± 490 kPa (4950 ± 72 psi)

34300 ± 490 kPa (4950 ± 72 psi)

32340 to 34790 kPa (4700 to 5050 psi)

50 ± 10 Nm (37 ± 7 lb ft)

36800 + 1470 kPa (5350 ±215 psi)

36800 ± 1470 kPa (5350 ± 215 psi)

33850 to 38270 kPa (4920 to 5565 psi)

20 ± 2 Nm (14 ± 4 lb ft)

Table 26

Required Tools Part Number

Description

Qty

9U-7400

Multitach Tool Group

1

8T-0470

Thermometer group

1

Table 27

Relief Valves

Pressure change With One Turn Of Adjustment Screw

Main valves

14400 kPa (2100 psi)

Line relief valve

11000 kPa (1600 psi)

Note: Pressure values in Table 27 are approximate values. Use a pressure gauge for adjustment.

Note: Normal operations of the engine and pumps are necessary for the pressure adjustments. If the results of the pressure adjustment are not correct, then the engine and the pump characteristic curve needs to be checked. Slow output flow from the pump is an indication of air in the hydraulic system.

Make sure that no air is present in the hydraulic system. Refer to Testing And Adjusting, "Air (Main Hydraulic Pump) - Purge".

Note: Always make final pressure adjustments on pressure rise.

Illustration 38 Pump compartment (1) Pressure tap for delivery pressure from the right pump (drive pump) (2) Pressure tap for delivery pressure from the left pump (idler pump) (3) Pressure tap (power shift pressure)

1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

4. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (1). Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (2).

5. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (3). This is used to monitor power shift pressure.

6. Start the engine.

7. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing And Adjusting, "Engine Performance Test" for engine rpm settings.

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

32 Hydraulic System Testing and Adjusting Section 9. Slowly move the joystick for the bucket to the BUCKET OPEN position (bucket cylinder rod at the fully retracted position).

10. Check the main relief valve pressure setting at pressure tap (1).

11. Return the joystick for the bucket to the NEUTRAL position.

12. The main relief valve pressure setting should be 34300 ± 490 kPa (4950 ± 72 psi). If the main relief valve is not within the specification, adjust the main relief valve pressure setting to the correct pressure specification before performing Step 13. Refer to Testing and Adjusting, "Main Relief Valve - Test and Adjust".

17. Check the pressure in the boom cylinder head end on the pressure gauge at pressure tap (1).

18. Return the joystick for the boom to the NEUTRAL position.

19. The pressure setting of the boom line relief valve is read at pressure tap (1). The pressure setting of the boom line relief valve should be 36800 ± 1470 kPa (5350 ± 2 1 5 psi). If the boom lowering control valves are set at a lower pressure, the boom lowering control valves will relieve pressure first. A lower pressure will be read. Continue to step 20.

20. A temporary setting of the head end of the boom line relief valve is required before the boom lowering control valve can be adjusted.

To make the temporary setting, loosen locknut (14) on the line relief valve for the head end of the boom cylinder. Turn adjustment screw (15) for one half turn. Tighten the locknut. This should ensure that the line relief valve is high enough.

21. The following test and adjustment procedures properly set the boom lowering control valves on each of the boom cylinders. The temporary settings of the main relief valve and the line relief valve must be performed before the boom lowering control valves are set.

Illustration 39

900666196

Top of main control valve

22. During the following procedure, carefully note the number of turns for adjustment screw (19).

Also, take note of the direction of the turns.

(4) Adjustment screw (5) Locknut (6) Main relief valve

13. A temporary setting of the main relief valve is required before any line relief valve can be adjusted. To make the temporary setting, loosen locknut (5) and turn adjustment screw (4) clockwise for one half turn. Tighten locknut (5).

Use the torque specification in Table 25.

14. Refer to Systems Operation/Testing and Adjusting, RENR 3814, "320C Excavator Engine and Pump Control", "Using Service Mode". Start service mode. Adjust the power shift pressure.

Input a fixed power shift pressure of 2900 kPa (420 psi).

15. The permanent pressure setting for the head end of the boom cylinder is 36800 ± 1470 kPa (5350 ± 2 1 5 psi).

16. To adjust the line relief valve pressure setting of the boom cylinder head end, move the joystick for the boom until the boom is at the full BOOM RAISE position (full extension of boom cylinders).

Hold the joystick for the boom in this position.

Illustration 40 (19) (20) (21) (22) (23)

Adjustment screw Locknut Relief valve Boom lowering control valve Manual valve for boom lowering

23. Loosen locknut (20) on the boom lowering control valve for the left cylinder. Turn adjustment screw (19) clockwise until the adjustment screw contacts the bottom. Do not overtighten adjustment screw (19). Be sure to remember the number of turns. Tighten locknut (20).

24. Move the joystick for the boom to the full BOOM RAISE position. Hold the joystick for the boom in this position and check the pressure gauge reading at pressure tap (1).

25. Return the joystick for the boom to the NEUTRAL position.

26. The pressure gauge reading should be 36800 ± 1500 kPa (5350 ± 215 psi). If the pressure gauge reading at pressure tap (1) is not within the specification, adjust the relief valve on the right cylinder. In order to adjust the relief valve, loosen locknut (20) on the right boom lowering control valve. Turn adjustment screw (19). Tighten the locknut.

27. Recall the number of clockwise turns on the left boom lowering control valve. Loosen locknut (20) on the left boom lowering control valve. Reverse adjustment screw (19). Make the recalled number of turns. Make one additional quarter turn in order to decrease the pressure setting below 36800 ± 1500 kPa (5350 ± 215 psi).

Tighten the locknut.

28. Fully extend the boom cylinders. Hold the implement control lever in the Boom Raise position. Read the pressure at pressure tap (1).

29. Return the joystick for the boom to the NEUTRAL position.

30. The pressure gauge reading should be 36800 ± 1500 kPa (5350 ± 2 1 5 psi). If the pressure gauge reading at pressure tap (1) is not within the specification, adjust the relief valve. In order to adjust the relief valve, loosen locknut (20) on the left boom lowering control valve. Turn adjustment screw (19). Tighten the locknut.

31. Reset the line relief valve for the head end of the boom cylinder. Refer to Testing and Adjusting, RENR3817, "Relief Valve (Line) - Test and Adjust".

32. Refer to Systems Operation/Testing and Adjusting, RENR3814, "320C Excavator Engine and Pump Control", "Using Service Mode". Exit service mode.

33. Reset the main relief valve pressure after resetting the line relief valve. Refer to Testing and Adjusting, RENR3817, "Relief Valve (Main) Test and Adjust".

34 Hydraulic System Testing and Adjusting Section

Pump Flow Measurement and Adjustment Main Pump (Flow) - Test (Constant Horsepower Flow Control) SMCS Code: 5070-081-FW This test measures individual pump flow at the pump. Each pump is tested individually for output flow at specified pressures. The pump that is not being tested is not under load and the pump remains at low pressure standby.

Illustration 41 The electronic control module is located in the compartment behind the cab.

(1) Alarm lamp (2) Electronic control module

Illustration 42 (3) Monitor (4) Message display

Note: Before starting main pump flow tests, check message display (4) on monitor (3) and alarm lamp (1) on electronic control module (2) for normal operation. If no faults are present, perform the operational checks. Refer to Testing And Adjusting, "Operational Checks".

Note: If the operational checks (cycle time) indicate that slow speed of an implement is common to the circuits of one pump, the problem is most likely in the hydraulic system. Then perform the pump flow tests. Refer to Testing And Adjusting, "Main Pump (Flow) - Test".

Note: The engine, the fuel, or the working altitude may be the problem if the operational checks indicate that slow speed of an implement is common to both pump circuits.

35 Hydraulic System Testing and Adjusting Section

Illustration 43 Flow meter tool layout (1) Swing motor (2) Connector at swing motor (3) 6V - 9840 Swivel tee (4) Makeup Line (swing motor) (6) Negative flow control line (right pump) (10) 4C-9910 Portable hydraulic tester (flow meter) (11) Delivery line (left pump) (12) Delivery line (right pump) (13) Negative flow control line (left pump)

(17) (23) (24) (29) (30) (31) (32) (33) (34) (35)

9U-7335 Blocking cover Right pump Left pump 1U-8303 Fitting 5K-9090 O-Ring seal 5P-0201 Hose 5P-1010 Sleeve 4C-8767 Coupling 7M-8485 O-Ring seal 4C-6481 Coupler assembly

(36) (37) (38) (39) (40) (42) (46) (47) (48) (49)

4C-6482 Nipple assembly 4I-6141 Coupling 8C - 9026 Adapter 6K-6307 O-Ring seal 6V-9854 Swivel elbow 1P-3703 Rectangular seal 8T-4184 Bolt 8T-4223 Hard washer 6V-0400 Half flange 1U-8292 adapter

36 Hydraulic System Testing and Adjusting Section

Right Pump 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: Perform the test for the right pump and the test for the left pump one at a time.

Illustration 44 Circuit diagram (1) Swing motor (2) Connector (3) Tee (4) Makeup line (5) Main control valve (8) Pressure tap (left pump delivery pressure) (9) 8T-0861 Pressure gauge (10) 4C-9910 Portable hydraulic tester (flow meter) (11) Delivery line for left pump (12) Delivery line from right pump (16) Pressure tap (right pump delivery pressure) (17) 9U-7335 Blocking cover (20) 8T-0856 Pressure gauge (21) Engine (22) Multitach (23) Right pump (24) Left pump (40) Elbow (50) Pressure tap (power shift pressure)

Illustration 45 Pump compartment (8) Pressure tap (left pump delivery pressure) (12) Delivery line for right pump (16) Pressure tap (right pump delivery pressure) (23) Right pump (24) Left pump (50) Pressure tap (power shift pressure)

1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

4. Install the following tools in accordance with the flow meter tool layout and the circuit diagram.

Refer to Illustration 43 and Illustration 44. a. Disconnect delivery line (12) from right pump (23).

37 Hydraulic System Testing and Adjusting Section b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (12) by using bolts (46) and washers (47). c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on right pump (23) by using half flanges (48), bolts (46) and washers (47).

Left Pump 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: Perform the test for the right pump and the test for the left pump one at a time.

•ustration 46 Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

d. Disconnect makeup line (4) from connector (2) at swing motor (1). e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1). f. Install seal (30) and makeup line (4) to tee (3). g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at right pump (23) and coupling (37) at the swing motor. h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (16) for right pump delivery pressure. i. Install multitach group (22) on engine (21).

This is used to monitor engine speed.

Illustration 47 Pump compartment (8) Pressure tap (left pump delivery pressure) (11) Delivery line for left pump (16) Pressure tap (right pump delivery pressure) (23) Right pump (24) Left pump (50) Pressure tap (power shift pressure)

1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

4. Install the following tools in accordance with the flow meter tool layout and the circuit diagram.

Refer to Illustration 43 and Illustration 44. a. Disconnect delivery line (11) from left pump (24). b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (11) by using bolts (46) and washers (47).

38 Hydraulic System Testing and Adjusting Section c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on left pump (24) by using half flanges (48), bolts (46) and washers (47).

WARNING To prevent personal injury and/or equipment damage from failed lines or components while the hydraulic test equipment is returned to the open flow position, slowly open the hydraulic test equipment valve while monitoring the pump flow.

If pump flow does not increase as the valve is opened, shut the engine off and determine what is preventing the pump from upstroking.

1. Start the engine.

2. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF, Refer to Testing And Adjusting, "Engine Performance - Test" for engine rpm settings.

illustration 48

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

Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

d. Disconnect makeup line (4) from connector (2) at swing motor (1). e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1). f. Install seal (30) and makeup line (4) to tee (3). g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at right pump (23) and coupling (37) at the swing motor. h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (8) for left pump delivery pressure. i. Install multitach group (22) on engine (21).

This is used to monitor engine speed.

Test Note: Perform the test for the front pump and the test for the rear pump one at a time.

WARNING To prevent personal injury or equipment damage from failure of the hydraulic test equipment or associated circuit components because of blocked pump flow, make sure that the test equipment valves are fully open before starting the engine.

Illustration 49 Monitor (A) Message display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key (G) Cancel key (H) Set key (I) OK key (J) Menu key

39 Hydraulic System Testing and Adjusting Section 4. Start Service Mode and input a fixed power shift pressure of 2400 ± 50 kPa (350 ± 7 psi).

Note: Refer to Service Manual, "Engine And Pump Electronic Control System" for additional information on Service Mode.

a. Press menu key (J).

Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu mode will be cancelled and the previous display will be restored to message display (A).

5. In order to perform flow measurements for either one of the pumps, the other pump must not be under load.

b. Press down key (E) in order to highlight the menu item "SERVICE OPTIONS" on the message display. Press OK key (I). c. Input the password "FFF2". Press left key (D) or right key (F) in order to change the position of the flashing character. Press up key (C) or press down key (E) in order to change the value of the flashing character. Press OK key (I) after the correct password is displayed. d. Press down key (E) once in order to highlight the second line on the message display.

Illustration 50 Portable hydraulic tester (flow meter)

e. Press right key (F) repeatedly until "DEVICE TEST" appears on the message display. f. Press down key (E) in order to move down one line on the message display. g. Press right key (F) until the "PS PRV - FIXED" appears on the message display. h. Press down key (E).

(10) Portable hydraulic tester (flow meter) (22) Multitach (26) Valve

6. Turn valve (26) on portable hydraulic tester (10) clockwise. Record pump flow at each of the following pressures in Table 28. Use pressure gauge (9) at pressure tap (16) to monitor right pump delivery pressure or use pressure tap (8) to monitor left pump delivery pressure.

i. Press OK key (I). The display on line 4 of the message display will now change to a numeric value. These characters represent the power shift pressure (kPa). j. Press left key (D) or right key (F) in order to increase or decrease the numeric value that is displayed on line 4 of the message display.

Pressing left key (D) one time decreases the power shift pressure 10 kPa (1.5 psi).

Pressing right key (F) one time increases the power shift pressure 10 kPa (1.5 psi).

Note: The value for power shift pressure on the monitor may not always match the pressure reading on the pressure gauge. Adjust the value on the monitor until the desired power shift pressure is attained on the pressure gauge that is connected to the pressure tap for power shift pressure. The actual power shift pressure must be 2400 ± 50 kPa (350 ± 7 psi) on the pressure gauge. k. Press up key (C). "SUCCESS" should appear on the message display.

Note: To prevent a change in power shift pressure during the pump flow test, do not turn the engine start switch to the OFF position.

Illustration 51 P-Q characteristic curve

40 Hydraulic System Testing and Adjusting Section Table 28 Pump Flow Test Measuring Points

Flow measured liter/min (US gpm)

9800 kPa (1425 psi)

15700 kPa (2300 psi)

19600 kPa (2850 psi)

25500 kPa (3700 psi)

29400 kPa (4250 psi)

110 ± 10 ' 86 ±10 (29.0 ± 2.6) (22.7 ± 2.6)

75 ± 10 (19.8 ± 2 . 6 )

Right Pump Left Pump

Oil temperature °C (°F)

Engine speed (rpm) Flow corrected liter/min (US gpm)

Right Pump

Specification for flow rate liter/min (US gpm)

New

172 ± 10 (45.4 ± 2.6)

135 ± 10 (35.6 ± 2.6)

Service limit

155 (41)

103(27)

Left Pump

Note: Specifications for output flow rates are based on an engine speed of 1800 rpm. To attain more accurate test results, measured flow should be corrected with the following calculation.

Table 29 Corrected flow

Note: Specifications for output flow rates are based on a power shift pressure at the pump of 2400 ± 50 kPa (350 ± 7 psi). The output flow rate changes approximately 6 L/min (1.6 US gpm) for each 100 kPa (14 psi) of power shift pressure in the lower range of the constant horsepower control.

The output flow rate changes approximately 3 L/min (0.8 US gpm) for each 100 kPa (14 psi) of power shift pressure in the higher range of the constant horsepower control.

83 (22)

56 (15)

48 (13)

Pump Control (Output Flow) Adjust SMCS Code: 3222-025-FW Adjust the pump output flow if the flow test results differ greatly from the specifications.

Adjustment of Pump Output Flow (Constant Horsepower Control)

Note: If the output flow rate of the pump is not within the specification, disconnect the negative flow control line from the pump that is being tested and perform the test again.

Note: Flow measurements must be done only during pressure rise.

Illustration 52 Main pump compartment (20) (21) (22) (23) (24) (25) (26) (27)

Adjustment Locknut Adjustment Locknut Adjustment Locknut Adjustment Locknut

screw screw screw screw

41 Hydraulic System Testing and Adjusting Section Adjust the flow of the right pump for the first stage of the constant horsepower control. The left pump must be at no-load condition.

Adjustment of the Maximum Output Flow of the Pump

1. Loosen locknut (23).

2. Turn adjustment screw (22) in order to adjust the output flow of the pump. Turning adjustment screw (22) clockwise will increase the output flow of the pump. Turning adjustment screw (22) counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment screw (22) will change the output flow of the pump at the following pressure.

• Output flow of the pump will change approximately 19 L/min (5.0 US gpm) if the output flow is adjusted in the pressure range of 11800 kPa (1700 psi) to 19600 kPa (2850 psi).

The pump is operating in the first stage of the constant horsepower control.

3. Tighten locknut (23) to a torque of 98 ± 9.8 N-m (70 ± 7 lb ft).

Adjust the flow of the right pump for the second stage of the constant horsepower control. The left pump must be at no-load condition.

1. Loosen locknut (21).

2. Turn adjustment screw (20) in order to adjust the output flow of the pump. Turning adjustment screw (20) clockwise will increase the output flow of the pump. Turning adjustment screw (20) counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment screw (20) will change the output flow of the pump at the following pressure.

• Output flow of the pump will change approximately 13 L/min (3.4 US gpm) if the output flow is adjusted in the pressure range of 27500 kPa (4000 psi) to 34300 kPa (4950 psi).

The pump is operating in the second stage of the constant horsepower control.

3. Tighten locknut (20) to a torque of 28 ± 7 N-m (21 ± 5 lb ft).

Adjust the left pump in the same manner as the right pump. Use locknut (27) and adjustment screw (26) in order to adjust the first stage of the constant horsepower control. Use locknut (25) and adjustment screw (24) in order to adjust the second stage of the constant horsepower control.

Main pump compartment (28) (29) (30) (31)

Adjustment screw Locknut Locknut Adjustment screw

Adjust the maximum output flow of the right pump.

1. Loosen locknut (30).

2. In order to adjust maximum output flow, turn adjustment screw (31). Turning adjustment screw (31) clockwise will decrease the maximum output flow of the pump. Turning adjustment screw (31) counterclockwise will increase the maximum output flow of the pump. A 1/4 turn of adjustment screw (31) will change the maximum output flow approximately 5 L/min (1.3 US gpm).

3. Tighten locknut (31) to a torque of 177 ± 15 N-m (130 ± 11 lb ft).

Adjust the maximum output flow of the left pump in the same manner as the right pump. Use locknut (29) and adjustment screw (28) in order to adjust the maximum output flow of the left pump.

Pump Control (Negative Flow) - Test SMCS Code: 3222-081-FW This test measures individual pump flow at the pump while a fixed negative flow control pressure is sent to the main pump regulator. Each pump is tested individually for an output flow rate at a specified delivery pressure and a specified negative flow control pressure.

42 Hydraulic System Testing and Adjusting Section

Illustration 54 Flow meter tool layout (1) Swing motor (2) Connector at swing motor (3) 6V-9840 Swivel tee (4) Makeup Line (swing motor) (6) Negative flow control line (right pump) (10) 4C-9910 Portable hydraulic tester (flow meter) (11) Delivery line (left pump) (12) Delivery line (right pump) (13) Negative flow control line (left pump)

(17) (23) (24) (29) (30) (31) (32) (33) (34) (35)

9U-7335 Blocking cover Right pump Left pump 1U-8303 Fitting 5K-9090O-Ring seal 5P-0201 Hose 5P-1010 Sleeve 40-8767 Coupling 7M-8485 0-Ringseal 4C-6481 Coupler assembly

(36) 4C-6482 Nipple assembly (37)4I-6141 Coupling (38) 8C-9026 Adapter (39) 6K-6307O-Ring seal (40) 6V-9854 Swivel elbow (42) 1P-3703 Rectangular seal (46) 8T-4184Bolt (47) 8T-4223 Hard washer (48) 6V-0400 Half flange (49) 1U-8292 Adapter

43 Hydraulic System Testing and Adjusting Section

Right Pump 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: Perform the test for the right pump and the test for the left pump one at a time.

Illustration 55 Circuit diagram (1) Swing motor (2) Connector (3) Tee (4) Makeup line (5) Main control valves (6) Negative flow control line (right pump) (7) Plug (8) Pressure tap (left pump delivery pressure) (9) Pressure gauge (10) Portable hydraulic tester (flow meter) (11) Delivery line (left pump) (12) Delivery line (right pump) (13) Negative flow control line (left pump) (14) Pressure tap (power shift pressure)

(15) Tees (16) (17) (18) (20) (21) (22) (23) (24) (40)

Pressure tap (right pump delivery pressure) Blocking cover Test line Pressure gauge Engine Multitach group Right pump Left pump Elbow

Illustration 56 Pump compartment (6) Negative flow control line (right pump) (12) Delivery line (right pump) (14) Pressure tap (power shift pressure) (16) Pressure tap (right pump delivery pressure) (23) Right pump (24) Left pump

1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

4. Install the following tools in accordance with the circuit diagram. Refer to Illustration 55. a. Disconnect delivery line (12) from right pump (23). b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (12) by using bolts (46) and washers (47).

44 Hydraulic System Testing and Adjusting Section c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on right pump (23) by using half flanges (48), bolts (46) and washers (47).

Illustration 57

g00669270

Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

d. Disconnect makeup line (4) from connector (2) at swing motor (1). e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1). f. Install seal (30) and makeup line (4) to tee (3). g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at right pump (23) and coupling (37) at the swing motor. h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (16) for right pump delivery pressure. i. Install multitach group (22) on engine (21).

This is used to monitor engine speed.

Illustration 58 Tool setup (6) Negative flow control line (right pump) (7) 6V-9508 Face seal plug (13) Negative flow control line (left pump) (14) Pressure tap (power shift pressure) (15) 8T-8902 Tee (18) 177-7860 Hose assembly (19) Left pump regulator (20) 8T-0855 Pressure gauge (23) Right pump (24) Left pump (25) 6V-8397 0-Ring seal (27) 6V-9829 Cap (28) 3J -1907 O-Ring seal (41) 6V-3965 Fitting (43) 6V-4143 Coupler (44) Test hose (45) 6V-3989 Fitting

j. Disconnect negative flow control line (6) from right pump (23). Install seal (25) and plug (7) to the end of negative flow control line (6). k. Connect two tees (15) to the elbow at the negative flow signal pressure port of right pump (23). Install cap (27) to tee (15).

I. Connect one end of test hose (18) to tee (15). m. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure. n. Connect one end of test hose (44) to tee (15).

45 Hydraulic System Testing and Adjusting Section o. Connect 6000 kPa (870 psi) pressure gauge (20) to the other end of test hose (44).

Left Pump 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.

b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (11) by using bolts (46) and washers (47). c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) to left pump (24) by using half flanges (48), bolts (46) and washers (47).

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: Perform the test for the right pump and the test for the left pump one at a time.

Illustration 60

900669270

Swing motor (top view) (1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

d. Disconnect makeup line (4) from connector (2) at swing motor (1). e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1). f. Install seal (30) and makeup line (4)to tee (3).

Illustration 59 Pump compartment (8) Pressure tap (left pump delivery pressure) (11) Delivery line (left pump) (13) Negative flow control line (left pump) (14) Pressure tap (power shift pressure) (23) Right pump (24) Left pump

1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

4. Install the following tools in accordance with the circuit diagram. Refer to Illustration 55. a. Disconnect delivery line (11) from left pump (24).

g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at left pump (24) and coupling (37) at the swing motor. h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (8) for left pump delivery pressure. i. Install multitach group (22) on engine (21).

This is used to monitor engine speed.

46 Hydraulic System Testing and Adjusting Section o. Connect 6000 kPa (870 psi) pressure gauge (20) to the other end of test hose (44).

Test Note: Perform the test for the right pump and the test for the left pump one at a time.

WARNING To prevent personal injury or equipment damage from failure of the hydraulic test equipment or associated circuit components because of blocked pump flow, make sure that the test equipment valves are fully open before starting the engine.

WARNING To prevent personal injury and/or equipment damage from failed lines or components while the hydraulic test equipment is returned to the open flow position, slowly open the hydraulic test equipment valve while monitoring the pump flow.

Illustration 61

If pump flow does not increase as the valve is opened, shut the engine off and determine what is preventing the pump from upstroking.

Tool setup (6) Negative flow control line (right pump) (7) 6V-9508 Face Seal Plug (13) Negative flow control line (left pump) (14) Pressure tap (power shift pressure)

(15) 8T-8902 Tee (18) (19) (20) (23) (24) (25) (27) (28) (41) (43) (44) (45)

177-7860 Hose Assembly Left pump regulator 8T-0855 Pressure Gauge Right pump Left pump 6V-8397 O-Ring Seal 6V-9829 Cap 3J -1907 O-Ring Seal 6V-3965 Fitting 6V-4143 Coupler Test hose 6V-3989 Fitting

j. Disconnect negative flow control line (13) from left pump (24). Install seal (25) and plug (7) to the end of negative flow control line (13). k. Connect two tees (15) to the elbow at the negative flow signal pressure port of left pump (24). Install cap (27) to tee (15).

I. Connect one end of test hose (18) to tee (15). m. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure. n. Connect one end of test hose (44) to tee (15).

1. Start the engine.

2. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing And Adjusting, "Engine Performance - Test" for engine rpm settings.

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

47 Hydraulic System Testing and Adjusting Section e. Press right key (F) repeatedly until 'DEVICE TEST" appears on the message display. f. Press down key (E) in order to move down one line on the message display. g. Press right key (F) until the "PS PRV - FIXED' appears on the message display. h. Press down key (E). i. Press OK key (I). The display on line 4 of the message display will now change to a numeric value. These characters represent the power shift pressure (kPa). j. Press left key (D) or right key (F) in order to increase or decrease the numeric value that is displayed on line 4 of the message display.

Pressing left key (D) one time decreases the power shift pressure 10 kPa (1.5 psi).

Pressing right key (F) one time increases the power shift pressure 10 kPa (1.5 psi).

E

F

G

H

I

J

Illustration 62 Monitor (A) Message display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key (G) Cancel key (H) Set key (I) OK key (J) Menu key

4. Start Service Mode and input a fixed power shift pressure of 2350 kPa (340 psi).

Note: The value for power shift pressure on the monitor may not always match the pressure reading on the pressure gauge. Adjust the value on the monitor until the desired power shift pressure is attained on the pressure gauge that is connected to the pressure tap for power shift pressure. The actual power shift pressure must be 2350 kPa (340 psi) on the pressure gauge.

Note: To prevent a change in power shift pressure during the pump flow test, do not turn the engine start switch to the OFF position.

Note: Refer to Service Manual, "Engine and Pump Electronic Control System" for additional information on Service Mode.

a. Press menu key (J).

Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu mode will be cancelled and the previous display will be restored to message display (A). b. Press down key (E) in order to highlight the second menu item "SERVICE OPTIONS" on the message display. Press OK key (I). c. Input the password "FFF2". Press left key (D) or right key (F) in order to change the position of the flashing character. Press up key (C) or press down key (E) in order to change the value of the flashing character. Press OK key (I) after the correct password is displayed. d. Press down key (E) once in order to highlight the second line on the message display.

Illustration 63 Portable hydraulic tester (flow meter) (10) Portable hydraulic tester (flow meter) (22) Multitach (26) Valve

48 Hydraulic System Testing and Adjusting Section 5. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is 6850 kPa (1000 psi).

Flow measurements must be done in pressure rise.

6. Record the negative flow rate in Table 30.

Pump Control (Negative Flow) - Adjust SMCS Code: 3222-025-FW

Illustration 64 Pressure/Flow characteristic curve Table 30

Negative Flow Control at 2350 kPa (340 psi) Right pump Oil Temperature °C (°F)

Engine speed (rpm)

Left pump Right pump Left pump

Flow measured liter/min (US gpm)

Right pump

Row corrected liter/min (US gpm)

Right pump

Specification for negative flow rate liter/min (US gpm)

Left pump

Left pump

Illustration 65

New

108 ± 10 (29.0 ± 2.6)

Service limit

88 (23)

Note: Specifications for flow rates are based on an engine speed of 1800 rpm. To get more accurate test results, measured flow should be corrected with the following calculation.

Table 31 Corrected flow

g00668985

Pump regulator (right pump) (1) (2) (3) (4) (5) (6)

Bolt Cover Seal Spring seat Spring Shim

Perform the following steps in order to adjust the right pump.

1. Remove two bolts (1).

2. Remove cover (2) and seal (3).

3. Remove spring seat (4) and spring (5).

49 Hydraulic System Testing and Adjusting Section 4. Add shims (6) in order to increase the negative flow. Remove shims (6) in order to decrease the negative flow. Refer to Table 32 for available shims and shim thickness.

Note: A change of 0.1 mm (0.0039 inch) in shim thickness will change the negative flow rate 3 L/min (0.8 US gpm) at a negative flow control pressure of 2350 kPa (340 psi).

Table 32

Available Shims Part Number

Shim Thickness

099-3669 Shim

1.00 mm (0.0394 inch)

099-6109 Shim

1.05 mm (0.0413 inch)

099-6110 Shim

1.10 mm (0.0433 inch)

099-6111 Shim

1.15 mm (0.0453 inch)

099-6112 Shim

1.20 mm (0.0472 inch)

099-6113 Shim

1.25 mm (0.0492 inch)

099-6115 Shim

1.30 mm (0.0512 inch)

099-6117 Shim

1.35 mm (0.0531 inch)

099-6118 Shim

1.40 mm (0.0551 inch)

099-6119 Shim

1.45 mm (0.0571 inch)

099-6120 Shim

1.50 mm (0.0591 inch)

099-6121 Shim

1.55 mm (0.0610 inch)

099-6122 Shim

1.60 mm (0.0630 inch)

099-6123 Shim

1.65 mm (0.0650 inch)

099-6124 Shim

1.70 mm (0.0669 inch)

099-6125 Shim

1.75 mm (0.0689 inch)

099-6126 Shim

1.80 mm (0.0709 inch)

099-6127 Shim

1.85 mm (0.0728 inch)

099-6128 Shim

1.90 mm (0.0748 inch)

099-3670 Shim

1.95 mm (0.0768 inch)

5. Install shims (6) in the pump regulator.

6. Install spring (5). Install spring seat (4).

7. Install cover (2) and seal (3).

Note: Inspect seal (3). If the seal is damaged, replace the damaged seal with a new seal.

8. Install bolts (1). Tighten bolts (1) to a torque of 55 ± 10 N.m (40 ± 7 lb ft).

Adjust the left pump in the same manner as the right pump.

Gear Pump (Pilot) - Test SMCS Code: 5085-081 -GT

50 Hydraulic System Testing and Adjusting Section

Illustration 66 Flow meter tool layout (1) (2) (3) (4) (6) (7)

Swing motor Connector at swing motor 6V-9840 Swivel Tee Makeup line (swing motor) 6V-9509 Face Seal Plug 4C-9910 Portable hydraulic tester (flow meter) (8) Pilot line (delivery line from the pilot pump)

(9) Connector at pilot pump (10) Pilot filter (14) Pilot pump (30) 5K-9090 O-Ring Seal (31) 5P-0201 Hose (32) 5P-1010 Sleeve (33) 4C-8767 Coupling (34) 7M-8485 O-Ring Seal (35) 4C-6481 Coupler Assembly

WARNING To prevent personal injury or equipment damage from failure of the hydraulic test equipment or associated circuit components because of blocked pump flow, make sure that the test equipment valves are fully open before starting the engine.

(36) 4C-6482 (37)41-6141 (38) 8C-9026 (39) 6K-6307 (40) 6V-9854 (47) 41-6140 (48) 8C-8762 (49) 6V-8398

Nipple Assembly Coupling Adapter O-Ring Seal Swivel Elbow Coupling Elbow O-Ring Seal

51 Hydraulic System Testing and Adjusting Section

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.

1. Position the machine on level ground.

2. Stop the engine.

3. Release the pressure in the hydraulic system.

Refer to Testing And Adjusting, "Hydraulic System Pressure - Release".

Illustration 67 Circuit diagram (1) Swing motor (2) Connector (3) Tee (4) Makeup line (5) Main control valve (6) Plug (7) Portable hydraulic tester (8) Pilot line (9) Connector at pilot pump (10) Pilot filter (12) Engine (13) Multitach group (14) Pilot pump (40) Elbow

4. Install the following tools in accordance with the flow meter tool layout and the circuit diagram.

Refer to Illustration 66 and Illustration 67. a. Install multitach group (13) on engine (12). b. Remove pilot line (8) from the connector at pilot pump (14). c. Install seal (49) and plug (6) to the end of pilot line (8). d. Install seal (49) and elbow (48) to connector (9) at pilot pump (14). e. Install seal (34), coupling (47), seal (34) and nipple assembly (36) to elbow (48).

52 Hydraulic System Testing and Adjusting Section

Illustration 68

Illustration 69

Swing motor

Portable hydraulic tester (flow meter)

(1) Swing motor (2) Connector (3) Tee (4) Makeup line (40) Elbow

(7) Portable hydraulic tester (flow meter) (13) Multitach group (16) Valve (flow meter)

f. Disconnect makeup line (4) from connector (2) at swing motor (1). g. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing motor (1).

8. Turn valve (16) on portable hydraulic tester (7) clockwise until pressure gauge (11) on the portable hydraulic tester shows a reading of 4100 ± 200 kPa (595 ± 29 psi).

9. Record the pilot pump flow at 4100 ± 200 kPa (595 ± 29 psi) in Table 33.

Table 33

h. Connect portable hydraulic tester (7) and test hoses between nipple assembly (36) at the pilot pump and coupling (37) at the swing motor.

Pump Flow Test Oil temperature C° (F°) Engine speed (rpm)

5. Start the engine.

Flow measured liter/min (US gpm)

6. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to Testing And Adjusting, "Engine Performance - Test" for engine rpm settings.

Flow corrected liter/min (US gpm)

Specification for pump flow liter/min (US gpm)

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

New

36 + 2 (9.5 ± 0.5)

Service limit

30 (7.9)

Note: Specifications for pump flow are based on an engine speed of 1800 rpm. To get more accurate test results, measured flow should be corrected by the following calculation.

Table 34

Flow measurements must be done in pressure rise.

53 Hydraulic System Testing and Adjusting Section

Hydraulic Motor and Pump Performance Tests

3. Disconnect the case drain hose (1) from tee (2).

Place the open end of the case drain hose (1) into the container for measuring.

4. Install 6V-8398 O-Ring seal and 6V-9830 Cap on tee (2) of the swivel.

Swing Motor - Test (Measurement of Case Drain Oil) SMCS Code: 5058-081-ZW Table 35

Required Tools Part Number 6V-9830

Description

Qty

Cap

1

Container for Measuring

1

Illustration 71 Pilot manifold

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.

(3) Connector (4) Solenoid valve for swing parking brake

5. Disconnect connector (3) from the solenoid valve for swing parking brake (4).

6. Start the engine.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

7. Place the engine speed dial at position "10" and AEC switch OFF. Maintain the maximum no-load speed at 1860 ± 50 rpm.

Dispose of all fluids according to local regulations and mandates.

Reference: Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.

1. Stop the engine.

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

2. Release the pressure in the hydraulic system.

Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

9. Slowly move the swing joystick and make sure that the swing parking brake is activated.

10. Move the swing joystick fully for one minute.

Measure the case drain oil.

11. Stop the engine.

12. Connect connector (3) to the solenoid valve for swing parking brake (4).

13. Repeat this test procedure three times in order to obtain three measurements. For each test procedure, swing the upper structure to a different position.

Illustration 70 Swing motor compartment (1) Case drain hose (2) Tee

The following values specify the maximum acceptable flow of case drain oil when the swing relief pressure is set at 26000 ± 980 kPa (3750 ± 140 psi).

54 Hydraulic System Testing and Adjusting Section New swing motor Rebuilt swing motor

30 L/min (7.9 US gpm) 35 L/min (9.2 US gpm)

Travel Motor - Test (Measurement of Case Drain Oil) SMCS Code: 4351-081 Table 36

Required Tools Illustration 72

Part Number

Description

FT-2547

Track block assembly

1

6V-9509

Face Seal Plug

1

6V-8398

O-Ring Seal

1

Remote drain hose with an inside diameter of 20 mm (.78 inch)

1

Container for measuring

1

Qty

Sprocket (left track) (1) Sprocket (2) FT-2547 Track block assembly

3. Place track block assembly (2) in sprocket (1) in order to block forward left travel. Refer to Illustration 72.

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" fortools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

1. Stop the engine.

Illustration 73 Travel motor

2. Release the pressure in the hydraulic system.

Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

(3) (4) (5) (6) (7) (8)

6V-9509 Face seal plug 6V-8398 O-Ring seal Case drain hose Connector Remote drain hose Container for measuring

4. Disconnect case drain hose (5) from connector (6). Install plug (3) and seal (4) in the open end of case drain hose (5).

5. Connect one end of remote drain hose (7) to connector (6). Place the other end of remote drain hose into the container (8) in order to measure the case drain oil.

55 Hydraulic System Testing and Adjusting Section 6. Start the engine.

7. Place the engine speed dial at position "10" and AEC switch OFF. Maintain the maximum no-load speed at 1860 ± 50 rpm.

Reference: Refer to Testing and Adjusting, "Engine Performance - Test" for engine rpm settings.

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

9. Move the left travel lever forward fully for one minute.

10. Measure the amount of case drain oil.

11. Remove track block assembly (2) from sprocket (1).

12. Move the left travel lever in order to reposition the travel motor.

13. Place track block assembly (2) in sprocket (1) in order to block forward left travel.

14. Repeat Steps 9 through 13 in order to obtain three measurements of case drain oil.

The following values specify the maximum acceptable flow of case drain oil when the main relief valve pressure is set at 34300 ± 490 kPa (4950 ± 72 psi) and the travel crossover relief valves are set at 36800 ± 1470 kPa (5350 ±215 psi).

New travel motor Rebuilt travel motor

15 L/min (4.0 US gpm) 18 L/min (4.78 US gpm)

56 Hydraulic System Testing and Adjusting Section

Reference Specifications Specifications SMCS Code: 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.

Illustration 74 Relief valve locations (A) Main relief valve (B) Boom cylinder line (head end) (C) Boom cylinder line (rod end) (D) Stick cylinder line (head end) (E) Stick cylinder line (rod end) (F) Bucket cylinder line (head end) (G) Bucket cylinder line (rod end) (H) Swing (right) (I) Swing (left)

(J) Left travel crossover relief valve for forward travel (upper valve) (K) Left travel crossover relief valve for reverse travel (lower valve) (L) Right travel crossover relief valve for forward travel (upper valve) (M) Right travel crossover relief valve for reverse travel (lower valve) (N) Pilot relief valve

(O) Main control valve (P) Pilot filter (Q) Travel motor (right) (R) Travel motor (left) (S) Swing motor

57 Hydraulic System Testing and Adjusting Section Table 37

Specifications Relief Valve

(A) Main relief valve

New Rebuilt

Service Limit

34300 + 490 kPa (4950 ± 72 psi)

32340 to 34790 kPa (4700 to 5050 psi)

Torque for Locknut

CHS Inspection Step NumberO)

50 ± 10 N-m (37 ± 7 lb ft)

115

(B) Boom cylinder line (head end)

138

(C) Boom cylinder line (rod end) (D) Stick cylinder line (head end)

36800 ± 1470 kPa (5350 ±215 psi)

(E) Stick cylinder line (rod end)

33850 to 38270 kPa (4920 to 5565 psi)

136 20 ± 2 N-m (14 ± 1 lb ft)

134

(F) Bucket cylinder line (head end)

140

(G) Bucket cylinder line (rod end)

142

(H) Swing relief pressure (right)

26000 ± 980 kPa (3750 ± 140 psi)

(1) Swing relief pressure (left)

24040 to 26980 kPa (3465 to 3890 psi)

147 117.6 ± 10 N-m (85 ± 7 lb ft)

(J) Left travel crossover relief valve (forward) (K) Left travel crossover relief valve (reverse) (L) Right travel crossover relief valve (forward)

151

36800 ± 1470 kPa (5350 ± 215 psi)

33850 to 38270 kPa (4920 to 5565 psi)

154 130 ± 13 N-m (95 ± 10 lb ft)

(M) Right travel crossover relief valve (reverse) (N) Pilot relief valve

145

157 160

4100 ± 200 kPa (595 ± 29 psi)

49 ± 4.9 N-m (36 ± 4 lb ft)

50

(1) Custom Hydraulic Service (CHS) is a preventive maintenance program for the machine hydraulic system. CHS is also a valuable part of any Customer Support Agreement. Refer to Custom Hydraulic Service, SEBF8472.

58 Hydraulic System Testing and Adjusting Section Table 38 Cycle Times (seconds) Factory

CHS Inspection Step Number*1)

Boom EXTEND

2.8 ± 0.5

192

Boom RETRACT

1.9 ± 0.5

Stick EXTEND

3.2 ± 0.5

195

Stick RETRACT

2.4 ± 0.5

197

Bucket EXTEND

3.3 ± 0.5

199

Bucket RETRACT

1.8 ± 0.5

201

5.2(2)

208

1100 mm (43.3 inch)<2>

209

Function

Swing LEFT Swing RIGHT Overswing LEFT Overswing RIGHT Forward travel HIGH (Left) 14.0(2) Reverse travel HIGH (Left) 217 Forward travel LOW (Left) 22.0(2) Reverse travel LOW (Left) Forward travel HIGH (Right) 14.0(2) Reverse travel HIGH (Right) 218 Forward travel LOW (Right) 22.0(2) Reverse travel LOW (Right) (1) Custom Hydraulic Service (CHS) is a preventive maintenance program for the machine hydraulic system. CHS is also a valuable part of any Customer Support Agreement. Refer to Custom Hydraulic Service, SEBF8472.

(2) Maximum Table 39 Cylinder Drift (Empty Bucket) Function

Factory

Boom cylinder

6.0 mm (0.24 inch)

Stick cylinder

10.0 mm (0.39 inch)

Bucket cylinder

10.0 mm (0.39 inch)

CHS Inspection Step Number*1) 228 237

(1) Custom Hydraulic Service (CHS) is a preventive maintenance program for the machine hydraulic system. CHS is also a valuable part of any Customer Support Agreement. Refer to Custom Hydraulic Service, SEBF8472.

Table 40 Required Tools Part Number

Description

Qty

9U-7400

Multitach Tool Group

1

8T-0470

Thermometer group

1

59 Hydraulic System Testing and Adjusting Section Table 41

Relief Valves

Pressure change With One Turn Of Adjustment Screw

Main valves

14400 kPa (2100 psi)

Line relief valve

11000kPa(1600psi)

Swing relief valve

6800 kPa (985 psi)

Travel crossover relief valve

3050 kPa (440 psi)

Pilot relief valve

620 kPa (90 psi)

Note: Pressure values in Table 41 are approximate values. Use a pressure gauge for adjustment.

Note: Normal operations of the engine and pumps are necessary for the pressure adjustments. If the results of the pressure adjustment are not correct, then the engine and the pump characteristic curve needs to be checked. Slow output flow from the pump is an indication of air in the hydraulic system.

Make sure that no air is present in the hydraulic system. Refer to Testing And Adjusting, "Main Hydraulic Pump Air Pressure - Purge".

Index c Control Valve (Boom Lowering) - Test and Adjust..

Cylinder Drift - Check (Empty Bucket) Cylinder Drift - Check (Loaded Bucket) Cylinder Speed - Check

30 16 15 17

E Engine Performance - Test (Engine Speed)

Pump Control (Negative Flow) - Test 41 Left Pump 45 Right Pump 43 Test 46 Pump Control (Output Flow) - Adjust 40 Adjustment of Pump Output Flow (Constant Horsepower Control) 40 Adjustment of the Maximum Output Flow of the Pump 41 Pump Flow Measurement and Adjustment 34

3 R

G Gear Pump (Pilot)-Test General Testing and Adjusting Information

49 4

H Hydraulic Motor and Pump Performance Tests 53 Hydraulic Pressure Adjustments 19 Hydraulic System Pressure - Release 4 Release Of Hydraulic Pressure From A Single Hydraulic Circuit 5 Release Of Hydraulic Pressure From Multiple Hydraulic Circuits 6

Reference Specifications Relief Valve (Crossover) - Test and Adjust Relief Valve (Line) - Test and Adjust Adjustment (Boom Cylinders) Adjustment (Bucket Cylinder) Adjustment (Stick Cylinder) Test Relief Valve (Main) - Test and Adjust Temporary Setting of the Main Relief Valve Relief Valve (Pilot) - Test and Adjust Relief Valve (Swing) - Test and Adjust Required Tools

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S I Important Safety Information

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M Machine Drift on a Slope - Check 12 Main Hydraulic Pump Air Pressure - Purge 7 Main Pump (Flow) - Test (Constant Horsepower Flow Control) 34 Left Pump , 37 Right Pump 36 Test 38

o Operational Checks

Solenoid Valve (Swing Parking Brake) - Test Specifications Swing Motor - Test (Measurement of Case Drain Oil) Swing Speed and Overswing on Level Ground Check., Swing Speed and Swing Drift on a Slope - Check..

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T Table of Contents , 3 Testing and Adjusting 4 Testing and Adjusting Section 4 Travel Motor - Test (Measurement of Case Drain Oil) 54 Travel on Level Ground - Test 11 Travel on Level Ground - Test (Optional Test) 10

9 V

P Visual Inspection Performance Tests Pump Control (Negative Flow) - Adjust...

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