330D Testing and Adjusting Hydraulic Systems RENR 9585

RENR 9585 Testing and Adjusting Hydraulic Systems •

General Testing and Adjusting Information 01/04/2006

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Visual Inspection 01/04/2006

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Hydraulic System Pressure - Release 01/04/2006 o Release Of Hydraulic Pressure From A Single Hydraulic Circuit 01/04/2006 o Release Of Hydraulic Pressure From Multiple Hydraulic Circuits 01/04/2006

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Main Hydraulic Pump Air - Purge 01/04/2006

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Operational Checks 01/04/2006

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Engine Performance - Test - Engine Speed 01/04/2006

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Travel on Level Ground - Test - Optional Test 01/04/2006

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Travel on Level Ground - Test 01/04/2006

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Machine Drift on a Slope - Check 01/04/2006

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Swing Speed and Overswing on Level Ground - Check 01/04/2006

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Swing Speed and Swing Drift on a Slope - Check 01/04/2006

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Cylinder Drift - Check - Empty Bucket 01/04/2006

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Cylinder Drift - Check - Loaded Bucket 01/04/2006

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Cylinder Speed - Check 01/04/2006

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Relief Valve (Pilot) - Test and Adjust 01/04/2006

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Accumulator (Pilot) - Test and Charge 01/04/2006 o Testing and Charging the Pilot System Accumulators 01/04/2006

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Relief Valve (Main) - Test and Adjust - Heavy Lift 01/04/2006 o Temporary Setting of the Main Relief Valve 01/04/2006

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Relief Valve (Line) - Test and Adjust 01/04/2006 o Test 01/04/2006 o Adjustment (Boom Cylinders) 01/04/2006 o Adjustment (Stick Cylinder) 01/04/2006 o Adjustment (Bucket Cylinder) 01/04/2006

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Swing Motor - Test - Crossover 01/04/2006

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Relief Valve (Swing) - Test and Adjust 01/04/2006

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Travel Motor - Test - Measurement of Case Drain Oil 01/04/2006

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Relief Valve (Crossover) - Test and Adjust 01/04/2006

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Main Pump (Flow) - Test - Constant Horsepower Flow Control 01/04/2006 o Drive Pump 01/04/2006 o Idler Pump 01/04/2006 o Test 01/04/2006

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Pump Control (Output Flow) - Adjust 01/04/2006 o Adjustment of Pump Output Flow (Constant Horsepower Control) 01/04/2006 o Adjustment of the Maximum Output Flow of the Pump 01/04/2006

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Pump Control (Negative Flow) - Test 01/04/2006 o Drive Pump 01/04/2006 o Idler Pump 01/04/2006 o Test 01/04/2006

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Pump Control (Negative Flow) - Adjust 01/04/2006

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Gear Pump (Pilot) - Test 01/04/2006

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Specifications 01/04/2006

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Previous Screen Product: EXCAVATOR Model: 330D L EXCAVATOR B6H Configuration: 330D L Excavator B6H00001-UP (MACHINE) POWERED BY C9 Engine

Testing and Adjusting 330D Excavator Hydraulic System Media Number -RENR9585-01

Publication Date -01/04/2006

Date Updated -17/04/2006 i01390735

General Testing and Adjusting Information SMCS - 5050

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. 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. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made. 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.

Copyright 1993 - 2007 Caterpillar Inc. All Rights Reserved.

Wed Feb 28 20:25:04 EST 2007

Private Network For SIS Licensees.

Shutdown




Date Updated -17/04/2006 i01134573

Visual Inspection SMCS - 5050-040 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.

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.

2. Remove the hydraulic filter elements. Inspect the hydraulic filters for material that would give an indication of damage to a component. 3. Inspect all lines and connections for damage or leaks. 4. Inspect control linkages for bent components, broken components or damaged components.

Copyright 1993 - 2007 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.

Wed Feb 28 20:25:43 EST 2007

Shutdown




Date Updated -17/04/2006 i01246594

Hydraulic System Pressure - Release SMCS - 4250-553-PX; 5050-553-PX The release of hydraulic pressure in a hydraulic circuit is required before service is performed to that hydraulic circuit. Release the pressure in the following hydraulic circuits before any hydraulic lines are disconnected or removed from that hydraulic circuit. z

Boom hydraulic circuit

z

Stick hydraulic circuit

z

Bucket hydraulic circuit

z

Swing hydraulic circuit

z

Travel hydraulic circuit

z

Attachment hydraulic circuits (if equipped)

z

Pilot hydraulic circuit

z

Return hydraulic circuit

Note: Refer to the Disassembly and Assembly Manual for additional information concerning service of the components of specific hydraulic circuits.

Release Of Hydraulic Pressure From A Single Hydraulic Circuit

Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is

not released before any service is done on the hydraulic system. Make sure all of the 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.


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

g00666865

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.

Release Of Hydraulic Pressure From Multiple Hydraulic Circuits

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.

Illustration 2

g00666865

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. 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.


Wed Feb 28 20:26:14 EST 2007

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Date Updated -17/04/2006 i02484921

Main Hydraulic Pump Air - Purge SMCS - 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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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 1 Pump compartment

g01240729

(1) Plug (2) Hose

1. While the engine is stopped, remove plug (1) . 2. Fill the main pumps with oil. 3. Install plug (1). Tighten plug (1) securely.

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

4. Start the engine. 5. Place the engine at low idle position. Raise the boom and hold the boom in this position. 6. Slowly loosen hose (2) until oil begins to flow around the hose connection. 7. Tighten hose (4) to the specified torque. 8. Stop the engine and slowly lower the boom until the work tool is on the ground. This pressurizes the hydraulic tank.

Illustration 2 (3) Plug

g01240743

9. Slowly loosen plug (3) until oil flows around plug (3). This will remove air from the system. 10. Tighten plug (3) securely.


Wed Feb 28 20:27:57 EST 2007

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Date Updated -17/04/2006 i02485029

Operational Checks SMCS - 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. Perform the following operational checks in order to troubleshoot problems concerning the hydraulic circuits and components on the machine. z

Testing and Adjusting, "Engine Performance - Test"

z

Testing and Adjusting, "Travel on Level Ground - Test"

z

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

z

Testing and Adjusting, "Machine Drift on a Slope - Check"

z

Testing and Adjusting, "Swing Speed and Overswing on Level Ground - Check"

z

Testing and Adjusting, "Swing Speed and Swing Drift on a Slope - Check"

z

Testing and Adjusting, "Cylinder Drift - Check (Empty Bucket)"

z

Testing and Adjusting, "Cylinder Drift - Check (Loaded Bucket)"

z

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 contains the machine configurations that were used in order to obtain these specifications. ReferenceRefer to Testing and Adjusting, "Engine Performance - Test" for the specifications for engine speed. Table 1

Machine Configuration Sales Model

Boom

330D

6.5 m (21 feet 4 inches)

330D L



Stick

Bucket


1.4 m3 (1.83 yd3)


1.5 m3 (1.96 yd3)

Wed Feb 28 20:28:47 EST 2007

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Date Updated -17/04/2006 i02485052

Engine Performance - Test - Engine Speed SMCS - 1000-081 Table 1 Required Tools Part Number

Description

Qty

9U-7400

Multitach Tool Group

1

1. Position the machine on level ground. 2. Stop the engine. 3. Install 9U-7400 Multitach Tool Group on the engine. 4. Start the engine. 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 2 for the specifications for engine speed at the desired engine operation. Table 2 Specifications Item New

Rebuild

1880 ± 50 rpm (2) No load high idle

Service Limit 1680 to 1930 rpm (1)

(1)

1980 ± 50 rpm (3) No load low idle Maximum speed with load (4)

800 ± 50 rpm 1720 rpm (5)

1670 rpm (5)

1780 to 2030 rpm (3) 800 ± 100 rpm 1620 rpm (5)

No load speed (6)

1300 ± 50 rpm

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

(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.


Wed Feb 28 20:29:36 EST 2007

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Date Updated -17/04/2006 i02485060

Travel on Level Ground - Test - Optional Test SMCS - 4351-081 Note: When the procedure for the Travel 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". Table 1 Required Tools Part Number

Description

Qty

Stopwatch

1

Illustration 1

g00297292

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 1. 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. Table 2 Time For Three Revolutions (time in seconds) Standard Undercarriage Travel Speed

New

Rebuild

Service Limit

22.5 or less

23.5 or less

24.5 or less

Forward HIGH Reverse

Forward LOW

34.5 or less

35.5 or less

36.5 or less

Reverse Table 3 Time For Three Revolutions (time in seconds) Long Undercarriage Travel Speed

New

Rebuild

Service Limit

24.5 or less

25.5 or less

26.5 or less

37.0 or less

38.0 or less

39.0 or less

Forward HIGH Reverse Forward LOW Reverse


Wed Feb 28 20:30:10 EST 2007

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Date Updated -17/04/2006 i02485146

Travel on Level Ground - Test SMCS - 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 1 Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

Illustration 1 (A) Preliminary run 5 m (16.4 ft)

g00296317

(B) Travel distance 20 m (65.6 ft) (C) Bucket height 0.5 to 1 m (1.6 to 3.3 ft)

1. Travel distance must be at least 25 m (82 ft) long. Travel test ground must be hard and as level as possible. 2. Draw a 25 m (82 ft) straight line on travel test ground as a reference line. 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 1. 8. Place the travel speed control switch in HIGH position. 9. Move the machine by operating both travel levers at the same time. 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.

Table 2 Travel Time (time in seconds) Travel Speed

New

Rebuild

Service Limit

15.2 or less

16.2 or less

17.2 or less

24.0 or less

25.5 or less

27.0 or less

Forward HIGH Reverse Forward LOW Reverse Note: The following table represents the travel deviation (distance) from the reference line. Table 3 Travel Deviation mm (inch) Travel Speed

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

Forward HIGH Reverse Forward LOW Reverse


Wed Feb 28 20:30:41 EST 2007

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Date Updated -17/04/2006 i01751979

Machine Drift on a Slope - Check SMCS - 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". Table 1 Required Tools Part Number

Description

Qty

Stopwatch

1

Scale 150 mm (6 inch)

1

Illustration 1

g00297342

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 1. 3. The bucket should be empty.

Illustration 2

g00297498

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 2.

5. Stop the engine. 6. Measure the machine movement on the slope after three minutes. Table 2 Drift mm (inch) New

Rebuild

0

0


Wed Feb 28 20:31:20 EST 2007

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Date Updated -17/04/2006 i02485170

Swing Speed and Overswing on Level Ground - Check SMCS - 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 1 Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

Illustration 1

g00297618

1. Position the machine on level ground. Refer to Illustration 1. 2. Stop the engine.

Illustration 2 (A) Upper frame (B) Undercarriage frame (C) Marking

g00293972

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 2. 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 2. Note: Use a point that is visible from the operator seat as a reference point for the target. Table 2 Overswing Item

New

Rebuild

Service Limit

Right Swing Left Swing

1300 mm (51.2 inch) or less



8. Move the swing joystick in each direction and measure the time that is required to complete a 180 degree swing operation. Table 3 Swing Time (seconds) Item

New

Rebuild

Service Limit

4.9 or less

5.4 or less

6.0 or less



Wed Feb 28 20:31:55 EST 2007

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Date Updated -17/04/2006 i02485189

Swing Speed and Swing Drift on a Slope - Check SMCS - 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. 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 1 Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

Illustration 1

g00298078

1. Complete the following steps in order to measure the swing speed on a slope. a. The work tool should be empty. b. Position the machine on a slope of 12 degrees. Refer to Illustration 1. c. Position the implements at maximum reach and close the work tool. Position the work tool above the ground so that the work tool will not come in contact with any obstacles.

Illustration 2

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 2. 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. g. Measure the time that is required to swing the upper structure from position (C) to position (B). Table 2 Swing Time (seconds) Item

New

Rebuild

Service Limit

5.5 or less

6.3 or less

7.0 or less

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

Illustration 3

g00298079

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 3.

Illustration 4 (A) Upper frame

g00293972

(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 4. c. Stop the engine. d. Leave the machine in this position for three minutes. Measure the swing drift on the circumference of the swing bearing. e. Start the engine. 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 3. g. Repeat Steps 2.b through 2.d. Table 3 Swing Drift mm (inch) Item

New

Rebuild

Service Limit

0

0

0



Wed Feb 28 20:32:34 EST 2007

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Date Updated -17/04/2006 i02485226

Cylinder Drift - Check - Empty Bucket SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 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. 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 1 Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

Illustration 1

g00298378

1. Position the machine on level ground. Refer to Illustration 1. 2. Empty the bucket. 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 2 Cylinder Drift (Empty Bucket) Item Boom Cylinder

Stick Cylinder

New

Rebuild

Service Limit

6.0 mm (0.24 inch) or less



10.0 mm ( 0.39 inch) or less



Bucket Cylinder





Wed Feb 28 20:33:28 EST 2007

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Date Updated -17/04/2006 i02485202

Cylinder Drift - Check - Loaded Bucket SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 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. 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 1 Required Tools Part Number

Description

Qty

5P-3277

Measuring Tape

1

Stopwatch

1

Illustration 1

g00298378

1. Position the machine on level ground. Refer to Illustration 1. 2. Load the bucket. Weight of bucket load 330D ... 2520 kg (5550 lb) 330D L ... 2700 kg (5950 lb) 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 three minutes. Measure each cylinder's length from cylinder pin to cylinder pin for drift. Table 2 Cylinder Drift (Loaded Bucket) Item Boom Cylinder

New 6.0 mm (0.24 inch) or less

Rebuild 12.0 mm (0.47 inch) or less

Service Limit 24.0 mm (0.94 inch) or less

Stick Cylinder

Bucket Cylinder








Wed Feb 28 20:34:19 EST 2007

Shutdown




Date Updated -17/04/2006 i02485261

Cylinder Speed - Check SMCS - 5456-535-VF; 5458-535-VF 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 1 (A) Extension test (B) Retraction test

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a. Place the machine on level ground. 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 1 for the operating speed of the boom cylinders. 2. Perform the following steps in order to test the operating speed of the stick cylinder.

Illustration 2 (A) Extension test

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(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. 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 1 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 3 (A) Extension test

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(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 1 for the operating speed of the bucket cylinder. Table 1 Cylinder Operating Speed (seconds)

Item Extension

New

Rebuild

Service Limit

3.4 ± 0.3

4.0 (1)

4.5 (1)

2.6 ± 0.3

3.3 (1)

3.8 (1)

3.4 ± 0.3

4.0 (1)

4.5 (1)

2.8 ± 0.3

3.5 (1)

4.0 (1)

4.4 ± 0.3

5.0 (1)

5.5 (1)

2.5 ± 0.3

3.2 (1)

3.7 (1)

Boom Retraction Extension Stick Retraction Extension Bucket Retraction (1)

Maximum


Wed Feb 28 20:34:59 EST 2007

Shutdown




Date Updated -17/04/2006 i02485276

Relief Valve (Pilot) - Test and Adjust SMCS - 5072-036 Table 1 Required Tools Part Number

Description

Qty

8T-0856

Pressure Gauge ( 6000 kPa (870 psi))

1

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".

Illustration 1 Pilot oil manifold compartment

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(28) Locknut (29) Adjustment screw (30) Pressure tap (31) Pilot filter

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 ± 30 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) . 11. Turn adjustment screw (29) until the pressure gauge reading at pressure tap (30) is 4100 ± 200 kPa (595 ± 30 psi). Note: Turn adjustment screw (29) clockwise in order to increase the pressure. Turn adjustment screw (29) counterclockwise in order to decrease the pressure. Note: Always make final pressure adjustments on pressure rise. 12. Tighten locknut (28) to a torque of 49 ± 4.9 N·m (36 ± 4 lb ft). 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.


Wed Feb 28 20:35:38 EST 2007

Shutdown




Date Updated -17/04/2006 i01927888

Accumulator (Pilot) - Test and Charge SMCS - 5077-045-PS; 5077-081-PS; 5077-081-PX

Dry nitrogen is the only gas approved for use in the accumulators. The charging of oxygen gas in an accumulator will cause an explosion. An explosion can be eliminated by using nitrogen gas cylinders with standard CGA (Compressed Gas Association, Inc.) No. 580 connectors. When nitrogen gas is ordered, make sure to order the cylinders with CGA No. 580 connectors. Do not rely on color codes or other methods of identification to tell the difference between nitrogen and oxygen cylinders. In any application, never use an adapter to connect your nitrogen charging group to a valve outlet used on both nitrogen, oxygen, or other gas cylinders. BE SURE YOU USE DRY NITROGEN (99.8% purity).


Table 1

REQUIRED TOOLS Part Number

Description

Quantity

175-5507

Nitrogen Charging Group

1

Testing and Charging the Pilot System Accumulators Stop the engine. Release the pressure from the pilot hydraulic system. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release". Gas pressure is variable with temperature. Check the temperature of the air around the accumulator. In order to check the amount of charge in an accumulator, the accumulator must be at the same temperature as the surrounding air. Note: The temperature of the accumulator may change as the accumulator is being charged due to the expansion or compression of the nitrogen charge. It may be necessary to charge the accumulator in several steps in order to ensure a correct charge. Table 2 Charge Pressures and Temperatures Temperature

Pressure

-25°C (-13°F)

1490 kPa (216 psi)

-20°C (-4°F)

1520 kPa (220 psi)

-15°C (5°F)

1550 kPa (225 psi)

-10°C (14°F)

1580 kPa (229 psi)

-5°C (23°F)

1610 kPa (233 psi)

0°C (32°F)

1640 kPa (238 psi)

5°C (41°F)

1670 kPa (242 psi)

10°C (50°F)

1700 kPa (247 psi)

15°C (59°F)

1730 kPa (251 psi)

20°C (68°F)

1760 kPa (255 psi)

25°C (77°F)

1790 kPa (260 psi)

30°C (86°F)

1820 kPa (264 psi)

35°C (95°F)

1850 kPa (268 psi)

40°C (104°F)

1880 kPa (273 psi)

45°C (113°F)

1910 kPa (277 psi)

50°C (122°F)

1940 kPa (281 psi)

If an accumulator has less than half of the required amount of precharge pressure, the accumulator should be charged. Oil in the accumulator will give an inaccurate precharge reading.

Illustration 1 Accumulator (Typical Example) (1) Cap

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Illustration 2 175-5507 Nitrogen Charging Group

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(2) Pressure gauge (3) Connection to the nitrogen cylinder (4) Regulator (5) Valve (6) Pressure gauge (7) Pressure regulating screw (8) Valve handle (9) Chuck

1. Make sure that valve (5) is closed. 2. Remove cap (1) from the accumulator. 3. Rotate valve handle (8) on chuck (9) counterclockwise until the valve handle reaches the full out position. Install chuck (9) on the accumulator. 4. Turn valve handle (8) clockwise until the valve is completely open. 5. Check the pressure reading on pressure gauge (6). Refer to Table 2 for the correct charging pressure and temperature relationship for the accumulator. 6. If the pressure reading on the gauge is too high, use the following steps in order to purge the nitrogen from the accumulator. a. Slowly open valve (5) .

b. Purge the nitrogen pressure until the pressure reading is within the specification. c. Close valve (5) . d. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely closed. e. Remove the test equipment. Replace cap (1) . 7. If the pressure is too low, use the following procedure to charge the accumulator: a. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely closed. b. Connect the 175-5507 Nitrogen Charging Group to the nitrogen cylinder with connection (3) . c. Connect the other end of the hose to valve (5) . d. Open the valve on the nitrogen cylinder. Make an adjustment to screw (7) on the regulator assembly until gauge (2) indicates the proper precharge pressure for the accumulator. Refer to Table 2. e. Open valve (5). Loosen chuck (9) slightly. Allow the nitrogen to purge the air from the hose. Tighten chuck (9) . f. Open valve (8) in order to charge the accumulator. g. Close valve (5) . h. The accumulator has the correct charge if the pressure on gauge (6) and the pressure on gauge (2) are equal and the gauge readings do not change. If there is a decrease in pressure on gauge (6), open valve (5) and allow more nitrogen to go into the accumulator. i. Repeat steps 7.d through 7.g until the following items occur:

The pressure on gauge (6) is equal to the pressure on gauge (2) .

There is no pressure change when valve (5) is closed.

j. Close valve (5). Close the valve on the nitrogen cylinder. k. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely closed. l. Remove the test equipment. Replace cap (1) .


Wed Feb 28 20:36:15 EST 2007

Shutdown




Date Updated -17/04/2006 i02532689

Relief Valve (Main) - Test and Adjust - Heavy Lift SMCS - 5069-025; 5069-081 Table 1 Required Tools Part Number

Description

Qty

Pressure Gauge 8T-0861

2 60000 kPa (8700 psi) Pressure Gauge

8T-0856

1 6000 kPa (870 psi)

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".


g01266656

(1) Pressure tap (pressure for drive pump) (2) Pressure tap (pressure for idler pump) (3) Pressure tap (power shift pressure)

3. Attach a 60000 kPa (8700 psi) pressure gauge to pressure tap (1) and pressure tap (2) . 4. Start the engine. 5. Exit the service mode. 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 (Engine Speed)" for engine rpm settings.

Illustration 2

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7. Set heavy lift switch (A) to the ON setting. Make sure that the indicator light is on. 8. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F). 9. Raise the boom until the boom cylinder rods are at full extension. 10. Check the main relief valve pressure setting at pressure tap (1) and pressure tap (2) . 11. Return the joystick for the boom to the NEUTRAL position.

Illustration 3 (4) Main Relief Valve

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(5) Locknut for the Main Relief Valve (6) Adjustment screw for the main relief valve (7) Locknut for the heavy lift (8) Adjustment screw for the heavy lift

12. The main relief valve pressure setting should be 36000 ± 500 kPa (5220 ± 73 psi). If the heavy lift relief valve pressure setting is not within the specification, adjust the heavy lift relief valve pressure setting. a. Loosen locknut (5) in order to adjust standard main relief valve (6). Tighten standard main relief valve (6) until the valve stops turning. Tighten locknut (5) . b. Loosen locknut (7) in order to adjust the relief valve for the heavy lift. The main relief valve is located on top of the main control valve. Adjust the pressure by turning adjustment screw for the heavy lift (8) until the pressure gauge reading at pressure tap (1) is 36000 ± 500 kPa (5220 ± 73 psi). Note: Turning adjustment screw (8) clockwise increases the pressure. Turning adjustment screw (8) counterclockwise decreases the pressure. c. Tighten locknut (7) to a torque of 75 ± 10 N·m (55 ± 7 lb ft). Note: Confirm the heavy lift pressure by fully retracting the stick cylinder. 13. Set heavy lift switch (A) to the OFF setting. The indicator light should not be illuminated. 14. Open the bucket until the bucket cylinder rod is at full retraction. 15. Check the main relief valve pressure setting at pressure tap (1) . 16. Return the joystick for the bucket to the NEUTRAL position.

17. The main relief valve pressure setting should be 35000 ± 500 kPa (5075 ± 72 psi). If the main relief valve pressure setting is not within the specification, adjust the main relief valve pressure setting. 18. In order to adjust the main relief valve, loosen locknut (5) and turn adjustment screw (6) until the pressure gauge reading at pressure tap (1) is 35000 ± 500 kPa (5075 ± 72 psi). Note: Always make final pressure adjustments on pressure rise. 19. Tighten locknut (5) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).

Temporary Setting of the Main Relief Valve Note: In order to adjust line relief valve pressure settings, the main relief valve must be temporarily adjusted to a higher setting since the line relief valve pressure settings are higher than the main relief valve pressure setting.

Illustration 4

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1. Set the heavy lift switch (A) to the ON setting. Make sure that the indicator light is ON. 2. The main relief valve pressure setting should be 36000 ± 500 kPa (5220 ± 73 psi) when the heavy lift mode is on. 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 3. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".

Illustration 5 (4) Main Relief Valve

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(5) Locknut for the Main Relief Valve (6) Adjustment screw for the main relief valve (7) Locknut for the heavy lift (8) Adjustment screw for the heavy lift

3. Loosen locknut (5) and tighten screw (6) until no adjustment is left. 4. Tighten locknut (5) while screw (6) is secured. 5. Loosen locknut (7) . 6. Tighten screw (8) until the pressure reading of tap (1) or (2) will not rise more. Read the pressure of tap (1) or (2) . 7. Turn screw (8) clockwise by a quarter turn. Tighten locknut (7) while screw (8) is secured. 8. Perform the desired steps for testing and adjusting the line relief valves. 9. Reset main relief valve pressure setting to the normal operating condition. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".


Wed Feb 28 20:39:47 EST 2007

Shutdown




Date Updated -17/04/2006 i02531991

Relief Valve (Line) - Test and Adjust SMCS - 5117-025-L9; 5117-081-L9 Table 1 Required Tools Part Number

Description

Qty

8T-0861

Pressure Gauge (60000 kPa (8700 psi))

2

8T-0856


1

Note: 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".


g01266656

(1) Pressure tap (delivery pressure for drive pump) (2) Pressure tap (delivery pressure for idler pump) (3) Pressure tap (power shift pressure)

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 (3) . 6. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (2) . This is used to monitor power shift pressure. 7. Start the engine. 8. Place the machine controls at the following settings: 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).

Illustration 2 Monitor

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(4) Up key (5) Left key (6) Down key (7) Right key (8) Cancel key (9) OK key (10) Set key (11) Menu key

10. Start Service Mode and input a fixed power shift pressure. Refer to Table 3 for the correct pressure setting of each hydraulic circuit. a. Press menu key (11) . Note: Make sure that the engine speed dial is set correctly. Refer to Table 3 for the correct setting.

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. b. Press right key (7) in order to highlight the menu item "SERVICE" on the message display. Press OK key (9) . c. Input the password "FFF2". Press left key (5) or right key (7) in order to change the character. Press "OK" key (9) or press "CANCEL" key (8) in order to delete the value of the flashing character. Press OK key (9) after the correct password is displayed. d. Press down key (6) repeatedly until "DEVICE TEST" appears on the message display. Press "OK" key (9) . e. Press down key (6) in order to move down one line on the message display. f. Press "OK" key (9) in order to select the "POWER SHIFT PRES" message display. g. Press "OK" key (9) . h. Press left key (5) or right key (7) in order to increase or decrease the numeric value that is displayed for the power shift pressure. Pressing left key (5) decreases the power shift pressure. Pressing right key (7) increases the power shift pressure. 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 (2) for power shift pressure. Make sure that the actual power shift pressure on the pressure gauge is correct for each hydraulic circuit. Refer to Table 3 for the correct power shift pressure. 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 3 Main control valves (front view)

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(12) Line relief valve (boom cylinder head end) (13) Line relief valve (bucket cylinder head end) (14) Line relief valve (stick cylinder rod end)

The following line relief valves are located on top of the main control valves: boom cylinder head end, bucket cylinder head end and stick cylinder rod end. The following line relief valves are located on the bottom of the main control valve: boom cylinder rod end, bucket cylinder rod end and stick cylinder head end.

Illustration 4 Line relief valve (typical example)

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(15) Locknut (16) Adjustment screw

Note: Turn adjustment screw (16) clockwise in order to increase the pressure. Turn adjustment screw (16) counterclockwise in order to decrease the pressure. 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. Table 2 Line Relief Valve Pressure Settings Standard Configuration Cylinder

Cylinder Position Retracted

Power Shift Pressure

Relief Pressure Setting

Heavy Lift Option Power Shift Pressure

Relief Pressure Setting

3200 ± 50 kPa 37000 ± 1000 (464 ± 7 psi) kPa (5350 ± 145 Speed Dial 3 psi)


Retracted



Extended



Retracted

2370± 50 kPa (344 ± 7 psi) Speed Dial 10

38000 ± 1000 kPa (5500 ± 145 psi)


Extended



Bucket Extended

Boom

Stick

Adjustment (Boom Cylinders) 1. To adjust the line relief valve pressure setting of the boom cylinder head end (12) , 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. 2. Check the pressure in the boom cylinder head end on the pressure gauge at pressure tap (1) and pressure tap (3) . 3. Return the joystick for the boom to the NEUTRAL position. 4. The pressure gauge reading should be 38000 ± 1000 kPa (5500 ± 145 psi). Refer to Table 3. If the pressure gauge reading at pressure tap (1) and pressure tap (3) is not within the specification, adjust the line relief valve . 5. In order to adjust the line relief valve, loosen locknut (15) on the boom line relief valve. Turn adjustment screw (16) until the pressure gauge reading at pressure tap (1) and pressure tap (3) is 38000 ± 1000 kPa (5500 ± 145 psi). Refer to Table 3. Note: Always make final pressure adjustment on pressure rise. 6. Tighten locknut (15) on the relief valve. 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 head end (13) must be performed. Note: Make sure that the engine speed dial and the power shift pressure for the BOOM DOWN hydraulic circuit is set correctly. Refer to Table 3 for the correct setting. 7. Loosen locknut (15) on the line relief valve for the BUCKET CLOSE function. Turn adjustment screw (16) by one quarter turn in a clockwise direction. Tighten locknut (15) on the line relief valve for the bucket cylinder. 8. Move the joystick for the bucket until the bucket is at the full BUCKET CLOSE position (full extension 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. 9. Check the pressure in the boom cylinder rod end on the pressure gauge at pressure tap (1) . 10. Return the joystick for the boom to the NEUTRAL position.

Illustration 5 Main control valves (front view)

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(17) Line relief valve (boom cylinder rod end) (18) Line relief valve (bucket cylinder rod end) (19) Line relief valve (stick cylinder head end)

11. The pressure gauge reading should be 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. If the pressure gauge reading at pressure tap (1) is not within the specification, adjust line relief valve (17) . 12. In order to adjust line relief valve (17) , loosen locknut (15) on the boom line relief valve. Turn adjustment screw (16) until the pressure gauge reading at pressure tap (1) is 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. Note: Always make final pressure adjustment on pressure rise. 13. Tighten locknut (15) on the boom line relief valve. 14. 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 valve (12) . Remove the line relief valve for the boom cylinder head end and the line relief valve for the stick cylinder rod end (14) from the main control valve. Exchange the location of the line relief valves. Adjust the pressure of the boom line relief valve that is now attached in the rod end. After completion of line relief valve adjustment, return the respective line relief valves to the original locations.

Adjustment (Stick Cylinder) Note: Make sure that the engine speed dial and the power shift pressure for the STICK OUT

hydraulic circuit is set correctly. Refer to Table 3 for the correct setting. 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. 2. Check the pressure in the stick cylinder rod end on the pressure gauge at pressure tap (1) and pressure tap (3) . 3. Return the joystick for the stick to the NEUTRAL position. 4. The pressure gauge reading should be 38000 ± 1000 kPa (5500 ± 145 psi). Refer to Table 3. If the pressure gauge reading at pressure tap (1) and pressure tap (3) is not within the specification, adjust the line relief valve. 5. In order to adjust the line relief valve, loosen locknut (15) on the stick line relief valve. Turn adjustment screw (16) until the pressure gauge reading at pressure tap (1) and pressure tap (3) is 38000 ± 1000 kPa (5500 ± 145 psi). Refer to Table 3. Note: Always make final pressure adjustment on pressure rise. 6. Tighten locknut (15) on the line relief valve. Note: Make sure that the engine speed dial and the power shift pressure for the STICK IN hydraulic circuit is set correctly. Refer to Table 3 for the correct setting. 7. To adjust the line relief valve pressure setting of the stick cylinder head end (19) , 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. Check the pressure in the stick cylinder head end on the pressure gauge at pressure tap (1) and pressure tap (3) . 9. Return the joystick for the stick to the NEUTRAL position. 10. The pressure gauge reading should be 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. If the pressure gauge reading at pressure tap (1) and pressure tap (3) is not within the specification, adjust the line relief valve. 11. In order to adjust the line relief valve, loosen locknut (15) on the stick line relief valve. Turn adjustment screw (16) until the pressure gauge reading at pressure tap (1) and pressure tap (3) is 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. Note: Always make final pressure adjustment on pressure rise. 12. After completion of line relief valve adjustment, tighten locknut (15) .

Adjustment (Bucket Cylinder) Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET CLOSE hydraulic circuit is set correctly. Refer to Table 3 for the correct setting. 1. To adjust the line relief valve pressure setting of the bucket cylinder head end (13) , 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. 2. Check the pressure in the bucket cylinder head end on the pressure gauge at pressure tap (1) . 3. Return the joystick for the bucket to the NEUTRAL position. 4. The pressure gauge reading should be 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. If the pressure gauge reading at pressure tap (1) is not within the specification, adjust the line relief valve. 5. In order to adjust the line relief valve, loosen locknut (15) on the bucket line relief valve. Turn adjustment screw (16) until the pressure gauge reading at pressure tap (1) is 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. Note: Always make final pressure adjustment on pressure rise. 6. Tighten locknut (15) on the line relief valve. Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET OPEN hydraulic circuit is set correctly. Refer to Table 3 for the correct setting. 7. To adjust the line relief valve pressure setting of the bucket cylinder rod end (18) , 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. 8. Check the pressure in the bucket cylinder rod end on the pressure gauge at pressure tap (1) . 9. Return the joystick for the bucket to the NEUTRAL position. 10. The pressure gauge reading should be 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. If the pressure gauge reading at pressure tap (1) is not within the specification, adjust the line relief valve for the bucket cylinder rod end. 11. In order to adjust the line relief valve, loosen locknut (15) on the bucket line relief valve. Turn adjustment screw (16) until the pressure gauge reading at pressure tap (1) is 37000 ± 1000 kPa (5350 ± 145 psi). Refer to Table 3. Note: Always make final pressure adjustment on pressure rise. 12. After completion of line relief valve adjustment, tighten locknut (15) . 13. Reset the main relief valve pressure to the correct setting. Refer to the adjustment procedures in Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".


Wed Feb 28 20:40:22 EST 2007

Shutdown




Date Updated -17/04/2006 i02489825

Swing Motor - Test - Crossover SMCS - 5058-081-ZW Table 1 Required Tools Part Number 6V-9830

Description

Qty

Cap

1

Wrench 24 mm (0.94 inch)

1

Container for Measuring

1


1. Stop the engine. 2. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

Illustration 1 Swing motor compartment

g01241688

(1) Case drain hose (2) Tee

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. 5. Turn the "SWING BREAK SOL" override to the ON position. a. Enter the service screen from the main menu. b. Select the OVERRIDE function. c. Highlight the SWING BREAK SOL line and turn to the ON position. Note: The SWING BREAK SOL will keep the swing brake applied while the joystick for the swing function is moved. 6. Start the engine. 7. Place the engine speed dial at position "10" and AEC switch OFF. Maintain the maximum noload speed at 1880 ± 50 rpm. ReferenceRefer 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. 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. Repeat this test procedure three times in order to obtain three measurements. For each test procedure, swing the upper structure to a different position. The following values specify the maximum acceptable flow of case drain oil when the swing relief pressure is set at 27900 ± 1000 kPa (4050 ± 145 psi). New swing motor ... 30 L/min (7.9 US gpm) Rebuilt swing motor ... 35 L/min (9.2 US gpm)


Wed Feb 28 20:40:58 EST 2007

Shutdown




Date Updated -17/04/2006 i02531999

Relief Valve (Swing) - Test and Adjust SMCS - 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".


g01266656

(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) . 5. Turn the "SWING BREAK SOL" override to the ON position.

a. Enter the service screen from the main menu. b. Select the OVERRIDE function. c. Highlight the SWING BREAK SOL line and turn to the ON position. Note: The SWING BREAK SOL will keep the swing brake applied while the joystick for the swing function is moved. 6. Start the engine. 7. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings. 8. Move the swing joystick slowly and ensure that the swing parking brake is operating properly.

Illustration 2 Swing motor

g01241747

(22) Adjustment plug (23) Locknut (25) Relief valve (left swing) (34) Adjustment plug (35) Locknut (36) Relief valve (right swing)

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 27900 ± 1000 kPa (4050 ± 145 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 27900 ± 1000 kPa (4050 ± 145 psi). Note: Turning adjustment plug (22) clockwise increases the pressure. Turning adjustment plug (22) counterclockwise decreases the pressure. Note: Always make final pressure adjustments on pressure rise. 13. Tighten locknut (23) to a torque of 120 ± 10 N·m (85 ± 7 lb ft). 14. Slowly move the swing joystick for a full SWING LEFT operation and check the pressure for relief valve (36) at pressure tap (2) . 15. Return the swing joystick to the NEUTRAL position. 16. The pressure setting of the swing relief valve is 27900 ± 1000 kPa (4050 ± 145 psi). If the pressure reading at pressure tap (2) is not within the specification, adjust the swing relief valve. 17. In order to adjust the swing relief valve, loosen locknut (35) . Turn adjustment plug (34) until the pressure gauge reading at pressure tap (2) is 27900 ± 1000 kPa (4050 ± 145 psi). Note: Turning adjustment plug (34) clockwise increases the pressure. Turning adjustment plug (34) counterclockwise decreases the pressure. Note: Always make final pressure adjustments on pressure rise. 18. Tighten locknut (35) to a torque of 120 ± 10 N·m (85 ± 7 lb ft). 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 (26) to the solenoid valve for swing parking brake (27) .


Wed Feb 28 20:41:30 EST 2007

Shutdown




Date Updated -17/04/2006 i01627732

Travel Motor - Test - Measurement of Case Drain Oil SMCS - 4351-081 Table 1 Required Tools Part Number

Description

Qty

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 1 20 mm (0.79 inch) Wrench 29 mm (1.14 inch)

1

Container for measuring

1


1. Stop the engine. 2. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic System Pressure - Release".

Illustration 1 Sprocket (left track)

g00714531

(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 1.

Illustration 2 Travel motor

g00714521

(3) 6V-9509 Face seal plug (4) 6V-8398 O-Ring seal (5) Case drain hose (6) Connector (7) Remote drain hose (8) 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. 6. Start the engine. 7. Place the engine speed dial at position "10" and AEC switch OFF. Maintain the maximum noload speed at 1880 ± 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 travel crossover relief valves are set at 36800 ± 1470 kPa (5350 ± 215 psi). New travel motor ... 15 L/min (4.0 US gpm) Rebuilt travel motor ... 18 L/min (4.8 US gpm)


Wed Feb 28 20:42:04 EST 2007

Shutdown




Date Updated -17/04/2006 i02532021

Relief Valve (Crossover) - Test and Adjust SMCS - 5069-036 Table 1 Required Tools Part Number

Description

Qty

8T-0861

Pressure Gauge (60000 kPa (8700 psi))

2

8T-0856


1

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.


g01266656

(1) Pressure tap (drive pump delivery pressure) (2) Pressure tap (delivery pressure for the idler pump) (3) Pressure tap (power shift pressure)

3. 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. 4. 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. 5. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (3) .

Illustration 2 Sprocket (left track)

g00714259

(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 2. 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 (Engine Speed)" for engine rpm settings.

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

Illustration 3 Monitor (A) Display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key

g01186552

(G) Back key (H) Home key (I) OK key (J) Menu key

10. Start Service Mode and input a fixed power shift pressure of 2850 kPa (415 psi). 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 Right key (F) in order to highlight "SERVICE" menu option. c. After the "SERVICE" option is highlighted, press OK key (I) .

Illustration 4

g01148206

d. After OK key (I) is pressed, the screen in Illustration 4 will be displayed. The password for the service menu is "FFF2". The keys for direction are used to input the password. Press Left key (D) or Right key (F) in order to change the position of the flashing character. Press OK key (I) in order to enter the highlighted character. e. After entering the last letter of the password, the monitor will continue with the

"SERVICE" screen. f. Repeatedly press down key (E) in order to highlight the "DEVICE TEST" line on the display. g. After the "DEVICE TEST" line is highlighted, press OK key (I) . h. Once the "DEVICE TEST" screen is displayed, press down key (E) until "POWER SHIFT PRES" appears on the display. i. When "POWER SHIFT PRES" is highlighted, press OK key (I) . j. The "POWER SHIFT PRES" will now be displayed. Line 4 of the display will now change to a numeric value. These characters represent the power shift pressure (kPa). k. 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 display. Pressing left key (D) decreases the power shift pressure. Pressing right key (F) increases the power shift pressure. 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 2850 kPa (415 psi) on the pressure gauge. 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 5 Travel brake valve (left side) (18) Locknut (19) Adjustment screw

g00671821

(20) Crossover relief valve (forward left travel) (21) Crossover relief valve (reverse left travel) (22) Locknut (23) 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 ± 1500 kPa (5350 ± 220 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 ± 1500 kPa (5350 ± 220 psi). Note: Turn adjustment screw (19) clockwise in order to increase the pressure. Turn adjustment screw (19) counterclockwise in order to decrease the pressure. Note: Always make final pressure adjustment on pressure rise. 14. Tighten locknut (18) to a torque of 90 ± 10 N·m (70 ± 7 lb ft). 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 REVERSE position and check the pressure gauge reading at pressure tap (2) . The pressure setting of crossover relief valve (21) should be 36800 ± 1500 kPa (5350 ± 220 psi). 17. Return the left travel control lever to the NEUTRAL position. 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 ± 1500 kPa (5350 ± 220 psi). Note: Turn adjustment screw (23) clockwise in order to increase the pressure. Turn adjustment screw (23) counterclockwise in order to decrease the pressure. Note: Always make final pressure adjustment on pressure rise. 19. Tighten locknut (22) to a torque of 90 ± 10 N·m (70 ± 7 lb ft). 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. 20. After relief valve adjustments, cancel Service Mode. 21. Return the main relief valve pressure to the specified setting after crossover relief valve pressure setting is attained. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".


Wed Feb 28 20:42:51 EST 2007

Shutdown




Date Updated -17/04/2006 i02486731

Main Pump (Flow) - Test - Constant Horsepower Flow Control SMCS - 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 1 g01241817 The electronic control module is located in the compartment behind the cab. (1) Alarm lamp (2) Electronic control module

Illustration 2 (3) Monitor

g01202106

(4) Message display

Note: Before starting main pump flow tests, check display (4) on monitor (3) and alarm lamp (1) on electronic control module (2) for normal operation. Lamp (1) should be green. If no faults are present, perform the operational checks. Refer to Testing and Adjusting, "Operational Checks". Note: If the operational checks 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, "Piston Pump (Main) - Test". Note: If the operational checks indicate that slow speed of an implement is common to both pump circuits, the problem may be in the engine, the fuel, or the working altitude.

Illustration 3

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 (drive pump) (10) 4C-9910 Portable hydraulic tester (flow meter) (11) Delivery line (idler pump) (12) Delivery line (drive pump) (13) Negative flow control line (idler pump)

g01241830

(17) 9U-7335 Blocking cover (23) Right pump (24) Idler pump (29) 1U-8303 Fitting (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 (36) 4C-6482 Nipple assembly (37) 4I-6141 Coupling (38) 8C-9026 Adapter (39) 6K-6307 O-Ring seal (40) 6V-9854 Swivel elbow (42) 1P-3703 Rectangular seal (46) 8T-4184 Bolt (47) 8T-4223 Hard washer (48) 6V-0400 Half flange (49) 1U-8292 Adapter

Illustration 4 Circuit diagram (1) Swing motor (2) Connector (3) Tee (4) Makeup line (5) Main control valve (8) Pressure tap (delivery pressure of the idler pump) (9) 8T-0861 Pressure gauge (10) 4C-9910 Portable hydraulic tester (flow meter)

g01202108

(11) Delivery line for idler 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) Idler pump (40) Elbow (50) Pressure tap (power shift pressure)

Drive 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 Dealer Service Tool Catalog" 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 drive pump and the test for the idler pump one at a time.


g01241832

(8) Pressure tap (delivery pressure of the idler pump) (12) Delivery line for drive pump (16) Pressure tap (drive pump delivery pressure) (23) Drive pump (24) Idler 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 3 and Illustration 4. a. Disconnect delivery line (12) from drive 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) . c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on drive pump (23) by using half flanges (48), bolts (46) and washers (47) .

Illustration 6 Swing motor (top view) (1) Swing motor

g00669270

(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 drive pump (23) and coupling (37) at the swing motor. h. Connect 4900 kPa (700 psi) pressure gauge (20) to tap (50) for power shift pressure. Connect 49000 kPa (7100 psi) pressure gauge (9) to tap (16) for drive pump delivery pressure. i. Install multitach group (22) on engine (21). This is used to monitor engine speed.

Idler 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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.



g01241834

(8) Pressure tap (delivery pressure of the idler pump) (11) Delivery line for idler pump (16) Pressure tap (drive pump delivery pressure) (23) Drive pump (24) Idler 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 3 and Illustration 4. a. Disconnect delivery line (11) from idler 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) . c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on idler pump (24) by using half flanges (48), bolts (46) and washers (47) .

Illustration 8 Swing motor (top view)

g00669270

(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 drive pump (23) and coupling (37) at the swing motor. h. Connect 4900 kPa (700 psi) pressure gauge (20) to pressure tap (50) for power shift pressure. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery pressure of the idler pump. i. Install multitach group (22) on engine (21). This is used to monitor engine speed.

Test Note: Perform the test for the drive pump and the test for the idler pump one at a time.

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.

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

Illustration 9 Monitor (A) Display (B) Keypad (C) Up key (D) Left key (E) Down key (F) Right key (G) Back key (H) Home key

g01202103

(I) OK key (J) Menu key

4. Start Service Mode and input a fixed power shift pressure of 1270 ± 50 kPa (185 ± 7.5 psi). 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 Right key (F) in order to highlight "SERVICE" menu option. c. After the "SERVICE" option is highlighted, press OK key (I) .

Illustration 10

g01148206

d. After OK key (I) is pressed, the screen in Illustration 10 will be displayed. The password for the service menu is "FFF2". The keys for direction are used to input the password. Press Left key (D) or Right key (F) in order to change the position of the flashing character. Press OK key (I) in order to enter the highlighted character. e. After entering the last letter of the password, the monitor will continue with the "SERVICE" screen. f. Repeatedly press down key (E) in order to highlight the "DEVICE TEST" line on the display.

g. After the "DEVICE TEST" line is highlighted, press OK key (I) . h. Once the "DEVICE TEST" screen is displayed, press down key (E) until "POWER SHIFT PRES" appears on the display. i. When "POWER SHIFT PRES" is highlighted, press OK key (I) . j. The "POWER SHIFT PRES" will now be displayed. Line 4 of the display will now change to a numeric value. These characters represent the power shift pressure (kPa). k. 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 display. Pressing left key (D) decreases the power shift pressure. Pressing right key (F) increases the power shift pressure. 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 kPa (350 psi) on the pressure gauge. 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. 5. In order to perform flow measurements for either one of the pumps, the other pump must not be under load.

Illustration 11 Portable hydraulic tester (flow meter) (10) Portable hydraulic tester (flow meter) (22) Multitach (26) Valve

g00670500

6. Turn valve (26) on portable hydraulic tester (10) clockwise. Record pump flow at each of the following pressures in Table 1. Use pressure gauge (9) at pressure tap (16) to monitor the drive pump delivery pressure or use pressure tap (8) to monitor the delivery pressure of the idler pump.

Illustration 12 P-Q characteristic curve

g01241842

Table 1 Pump Flow Test Measuring Points 9000 kPa 12000 (1300 kPa (1750 psi) psi)

Flow measured liter/min (US gpm)

Drive Pump Idler Pump

16000 kPa (2300 psi)

26000 kPa (3750 psi)

30000 kPa (4350 psi)

Oil temperature °C (°F)

Engine speed (rpm)

Flow corrected liter/min (US gpm)

Drive Pump Idler Pump

New

273 ± 10 (72 ± 2.6)

259 ± 10 (68 ± 2.6)

224 ± 10 (59 ± 2.6)

181 ± 10 (48 ± 2.6)

168 ± 10 (44 ± 2.6)

Service limit

262 (69)

217 (57)

188 (49)

137 (36)

127 (34)

Specification for flow rate liter/min (US gpm)

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 2 Measured flow x 1800 rpm Corrected flow

= measured rpm

Note: Specifications for output flow rates are based on a power shift pressure at the pump of 1270 ± 50 kPa (185 ± 7.5 psi). The output flow rate changes approximately 10 L/min (1.8 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. 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.


Wed Feb 28 20:43:47 EST 2007

Shutdown




Date Updated -17/04/2006 i02488042

Pump Control (Output Flow) - Adjust SMCS - 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)

Illustration 1

Main pump compartment (20) Adjustment screw (21) Locknut (22) Adjustment screw (23) Locknut (24) Adjustment screw

g01242465

(25) Locknut (26) Adjustment screw (27) Locknut

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. 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 29 L/min (7.7 US gpm) if the output flow is adjusted in the pressure range of 10000 kPa (1450 psi) to 21000 kPa (3050 psi). The pump is operating in the first stage of the constant horsepower control.

3. Tighten locknut (23) to a torque of 160 ± 24 N·m (120 ± 18 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 16 L/min (4.2 US gpm) if the output flow is adjusted in the pressure range of 28000 kPa (4050 psi) to 31000 kPa (4500 psi). The pump is operating in the second stage of the constant horsepower control.

3. Tighten locknut (20) to a torque of 16 ± 2.4 N·m (12 ± 1.8 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.

Adjustment of the Maximum Output Flow of the Pump

Illustration 2 Main pump compartment

g01242469

(28) Adjustment screw (29) Locknut (30) Locknut (31) 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 7 L/min (1.8 US gpm). 3. Tighten locknut (30) to a torque of 240 ± 36 N·m (175 ± 27 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.


Wed Feb 28 20:44:24 EST 2007

Shutdown




Date Updated -17/04/2006 i02488189

Pump Control (Negative Flow) - Test SMCS - 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.

Illustration 1

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 (drive pump) (10) 4C-9910 Portable hydraulic tester (flow meter) (11) Delivery line (idler pump) (12) Delivery line (drive pump) (13) Negative flow control line (idler pump)

g01242534

(17) 9U-7335 Blocking cover (23) Drive pump (24) Idler pump (29) 1U-8303 Fitting (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 (36) 4C-6482 Nipple assembly (37) 4I-6141 Coupling (38) 8C-9026 Adapter (39) 6K-6307 O-Ring seal (40) 6V-9854 Swivel elbow (42) 1P-3703 Rectangular seal (46) 8T-4184 Bolt (47) 8T-4223 Hard washer (48) 6V-0400 Half flange (49) 1U-8292 Adapter

Illustration 2 Circuit diagram (1) Swing motor (2) Connector (3) Tee (4) Makeup line (5) Main control valves (6) Negative flow control line (drive pump) (7) Plug (8) Pressure tap (delivery pressure for the idler pump)

g01189807

(9) Pressure gauge (10) Portable hydraulic tester (flow meter) (11) Delivery line (idler pump) (12) Delivery line (drive pump) (13) Negative flow control line (idler pump) (14) Pressure tap (power shift pressure) (15) Tees (16) Pressure tap (drive pump delivery pressure) (17) Blocking cover (18) Test line (20) Pressure gauge (21) Engine (22) Multitach group (23) Drive pump (24) Idler pump (40) Elbow

Drive 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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.



g01242537

(6) Negative flow control line (drive pump) (12) Delivery line (drive pump) (16) Pressure tap (drive pump delivery pressure) (23) Drive pump (24) Idler 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 2. a. Disconnect delivery line (12) from drive 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) . c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on drive pump (23) by using half flanges (48), bolts (46) and washers (47) .


g00669270


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 drive pump (23) and coupling (37) at the swing motor. h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (16) for drive pump delivery pressure. i. Install multitach group (22) on engine (21). This is used to monitor engine speed.

Illustration 5 Tool setup (6) Negative flow control line (drive pump) (7) 6V-9508 Face seal plug (13) Negative flow control line (idler pump) (14) Pressure tap (power shift pressure) (15) 8T-8902 Tee (18) 177-7860 Hose assembly (19) Idler pump regulator (20) 8T-0855 Pressure gauge

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(23) Drive pump (24) Idler pump (25) 6V-8397 O-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 drive 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 drive pump (23). Install cap (27) to tee (15) . l. 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) . o. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .

Idler 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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.



g01242540

(8) Pressure tap (delivery pressure for the idler pump) (11) Delivery line (idler pump) (13) Negative flow control line (idler pump) (23) Drive pump (24) Idler 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 2. a. Disconnect delivery line (11) from idler 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) . c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) to idler pump (24) by using half flanges (48), bolts (46) and washers (47) .


g00669270


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 idler pump (24) and coupling (37) at the swing motor. h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery pressure of the idler pump. i. Install multitach group (22) on engine (21). This is used to monitor engine speed.

Illustration 8 Tool setup (6) Negative flow control line (drive pump) (7) 6V-9508 Face seal plug (13) Negative flow control line (idler pump) (14) Pressure tap (power shift pressure) (15) 8T-8902 Tee (18) 177-7860 Hose assembly (19) Idler pump regulator (20) 8T-0855 Pressure gauge

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(23) Drive pump (24) Idler pump (25) 6V-8397 O-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 (13) from idler 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 idler pump (24). Install cap (27) to tee (15) . l. 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) . o. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .

Test Note: Perform the test for the drive pump and the test for the idler pump one at a time.

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.

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

Illustration 9 Monitor (A) Display (B) Keypad

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(C) Up key (D) Left key (E) Down key (F) Right key (G) Back key (H) Home key (I) OK key (J) Menu key

4. Start Service Mode and input a fixed power shift pressure of 1080 kPa (155 psi). 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 Right key (F) in order to highlight "SERVICE" menu option. c. After the "SERVICE" option is highlighted, press OK key (I) .

Illustration 10

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d. After OK key (I) is pressed, the screen in Illustration 10 will be displayed. The password for the service menu is "FFF2". The keys for direction are used to input the password. Press Left key (D) or Right key (F) in order to change the position of the flashing character. Press OK key (I) in order to enter the highlighted character. e. After entering the last letter of the password, the monitor will continue with the "SERVICE" screen. f. Repeatedly press down key (E) in order to highlight the "DEVICE TEST" line on the display. g. After the "DEVICE TEST" line is highlighted, press OK key (I) . h. Once the "DEVICE TEST" screen is displayed, press down key (E) until "POWER SHIFT PRES" appears on the display. i. When "POWER SHIFT PRES" is highlighted, press OK key (I) . j. The "POWER SHIFT PRES" will now be displayed. Line 4 of the display will now change to a numeric value. These characters represent the power shift pressure (kPa). k. 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 display. Pressing left key (D) decreases the power shift pressure. Pressing right key (F) increases the power shift pressure. 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 1080 kPa (155 psi) on the pressure gauge. 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 11 Portable hydraulic tester (flow meter)

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

5. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is 6900 kPa (1000 psi). 6. Record the negative flow rate in Table 1.

Illustration 12

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Pressure/Flow characteristic curve

Table 1 Negative Flow Control at 1080 kPa (155 psi) Drive pump Oil Temperature °C (°F) Idler pump Drive pump Engine Speed (rpm) Idler pump Drive pump Flow measured liter/min (US gpm) Idler pump Drive pump Flow corrected liter/min (US gpm) Idler pump New

150 ± 15 (40 ± 4)

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

120 (32)

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 2 Measured flow x 1800 rpm Corrected flow

= Measured rpm

Flow measurements must be done in pressure rise.


Wed Feb 28 20:44:59 EST 2007

Shutdown




Date Updated -17/04/2006 i02488499

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

Illustration 1 Pump Compartment

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(29) Adjustment screw (30) Locknut (31) Adjustment screw (32) Locknut

Note: Use the same procedure for both pumps. Use locknut (30) and adjustment screw (29) to adjust the drive pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump. 1. Loosen locknut (30) . 2. Turn adjustment screw (29) until the negative flow rate is adjusted to the correct specification. Note: A clockwise adjustment of adjustment screw (29) and adjustment screw (31) decreases

the flow rate. A counterclockwise adjustment increases the flow rate. Note: A quarter turn of adjustment screw (29) will change the flow rate approximately 21.5 L/min (5.5 US gpm) which is approximately 100 kPa (15 psi). 3. Tighten locknut (30) to a torque of 16 N·m (12 lb ft). 4. Adjust the idler pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump.


Wed Feb 28 20:45:39 EST 2007

Shutdown




Date Updated -17/04/2006 i02488550

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

Illustration 1 Flow meter tool layout (1) Swing motor (2) Connector at swing motor (3) 6V-9840 Swivel tee (4) Makeup line (swing motor) (6) 6V-9509 Face seal plug (7) 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 (36) 4C-6482 Nipple assembly (37) 4I-6141 Coupling (38) 8C-9026 Adapter (39) 6K-6307 O-Ring seal (40) 6V-9854 Swivel elbow (47) 4I-6140 Coupling (48) 8C-8762 Elbow (49) 6V-8398 O-Ring seal

To prevent personal injury or equipment damage from failure of the

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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.


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 2 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

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(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 1 and Illustration 2. a. Install multitach group (13) on engine (12) . b. Remove pilot line (8) from connector (9) 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) .

Illustration 3 Swing motor

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

Illustration 4 Portable hydraulic tester (flow meter)

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

8. Turn valve (16) on portable hydraulic tester (7) clockwise until the pressure gauge on the portable hydraulic tester shows a reading of 3900 kPa (565 psi). 9. Record the pilot pump flow at 4100 ± 200 kPa (595 ± 29 psi) in Table 1. Table 1 Pump Flow Test Oil Temperature C° (F°) Engine Speed (rpm) Flow Measured liter/min (US gpm) Flow Corrected liter/min (US gpm)

New

40.1 (11)

Specification for Pump Flow liter/min (US gpm) Service Limit

33 (8.7)

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 2 Measured flow x 1800 rpm Corrected flow

= Measured rpm

Flow measurements must be done in pressure rise.


Wed Feb 28 20:46:22 EST 2007

Shutdown




Date Updated -17/04/2006 i02488599

Specifications SMCS - 5050 S/N - B6H1-UP S/N - EDX1-UP S/N - JLP1-UP S/N - MWP1-UP

Illustration 1

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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

Table 1 Specifications Relief Valve

New Rebuilt (1) 35000 ± 500 kPa (5100 ± 72 psi)

(A) Main relief valve 36000 ± 500 kPa (5200 ± 72 psi) (Heavy Lift)

Service Limit (2)

33000 kPa (4800 psi) to 35500 kPa (5150 psi)

Torque for Locknut

69 ± 10 N·m (51 ± 7 lb ft)

50 ± 10 N·m (37 ± 7 lb ft)

(B) Boom cylinder line (head end)

38000 ± 1000 kPa (5500 ± 145 psi)

35600 kPa (5150 psi) to 39000 kPa (5650 psi)

37000 ± 1000 kPa (5400 ± 150 psi)

34600 kPa (5000 psi) to 38000 kPa (5500 psi)

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

20 ± 2 N·m (14 ± 1 lb ft) (E) Stick cylinder line (rod end)

38000 ± 1000 kPa (5500 ± 145 psi)

35600 kPa (5150 psi) to 39000 kPa (5650 psi)

37000 ± 1000 kPa (5300 ± 145 psi)

34600 kPa (5000 psi) to 38000 kPa (5500 psi)

27900 ± 1500 kPa (4050 ± 220 psi)

25900 kPa (3750 psi) to 28900 kPa (4200 psi)

117 ± 10 N·m (85 ± 7 lb ft)

36800 ± 1500 kPa (5337 ± 220 psi)

33800 kPa (4900 psi) to 38300 kPa (5555 psi)

92 ± 8 N·m (72 ± 6 lb ft)

(F) Bucket cylinder line (head end) (G) Bucket cylinder line (rod end) (H) Swing relief pressure (right) (I) Swing relief pressure (left) (J) Left travel crossover relief valve (forward) (K) Left travel crossover relief valve (reverse) (L) Right travel crossover relief valve (forward) (M) Right travel crossover relief valve (reverse) (N) Pilot relief valve (1) (2)

4100 ± 200 kPa (595 ± 29 psi)

49 ± 5 N·m (36 ± 4 lb ft)

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 the following problems: improper adjustment, wear, damage of relief valves and damage of pumps.

Table 2 Required Tools Part Number

Description

Qty

9U-7400

Multitach Tool Group

1

8T-0470

Thermometer group

1 Table 3

Relief Valves Main valves Line relief valve Swing relief valve Travel crossover relief valve Pilot relief valve

Pressure change With One Turn Of Adjustment Screw 14400 kPa (2100 psi) 11000 kPa (1600 psi) 6800 kPa (985 psi) 3050 kPa (440 psi) 620 kPa (90 psi)

Note: Pressure values in Table 3 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 - Purge".


Wed Feb 28 20:47:11 EST 2007

330D Testing and Adjusting Hydraulic Systems RENR 9585

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