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Bienvenido: pvaldez
Producto:  EXCAVATOR
Modelo:  322 L EXCAVATOR 9RL01230
Configuración: 322L EXCAVATOR 9RL00001-UP (MACHINE) POWERED BY 3116
ENGINE

Pruebas y Ajustes
322 & 322 L, 322 N, AND 322 LN EXCAVATORS HYDRAULIC SYSTEM
Número de medio -SENR6157-00 Fecha de publicación -06/06/1994 Fecha de actualización -12/10/2001
   

Testing and Adjusting

Introduction
NOTE: This manual is divided into the following two main sections:

1. Checking Procedures
2. Testing And Adjusting

NOTE: As a general rule, if there is a doubt as to the cause of a problem, the electronic system
should be checked first.

Reference: For information on Systems Operation of the above, make reference to: "Systems
Operation, Testing And Adjusting, Engine And Pump Electronic Control System", Form
SENR6155 and/or "Systems Operation, Hydraulic System", Form SENR6156.

This manual contains information on the troubleshooting procedures of the hydraulic systems
in the 322, 322 L, 322 N and 322 LN Excavators. For troubleshooting the engine components,
refer to the module Systems Operation, Testing And Adjusting, Basic Engine Components 3116
Engine, Form SENR3583.

Checking Procedures
In each checking procedure, it is assumed that the engine operation is normal unless
otherwise specified.

Electronic Control System

The monitor and electronic controller are the main components of the electronic control
system. The monitor and electronic controller have a self diagnostic function. Self diagnostic
checks of the monitor, electronic controller, and the communication line between them are the
first steps when troubleshooting the problem(s) in the electronic system.

Action alarm indicators on the monitor panel, alert an operator to a problem in the electronic
system. The controller service program "Data Mode" can also be used to identify the problems
(see the section of this module "Data Mode"). If the service program is activated during
machine operation, problem(s) that are monitored by the monitoring system are indicated on
the character display. If the service program is activated when the machine operation is
stopped, all existing problems and past problems (problems that have not been corrected) are
indicated on the character display. To activate the controller service program "Data Mode",
refer to the "Data Mode" section in this module.

Reference: For information on operation of the "Data Mode", make reference to: "Systems
Operation, Testing And Adjusting, Engine And Pump Electronic Control System", Form
SENR6155.

Operational Tests
If the electronic power unit control system display indicates it is operating correctly, then do
operational tests. Operate the machine, following the procedures described in the section
"Testing And Adjusting". Compare the results of the operational tests with specifications to
determine the extent of the trouble. In operational tests, it is important to determine whether
or not enough hydraulic force or implement speed is a problem that extends over the entire
machine or with only a specific operation.

If there are any faults in the circuits between the main or pilot pumps and the control valves,
the overall performance of the machine will decrease. This type of problem in the hydraulic
system is not detected by the self diagnostic functions of the electronic control system
described above (no action alarm indication on character display.). To detect such a problem, it
is necessary to check the flow characteristics of the pumps, the main relief pressure, pilot
pressure, etc.

Checking Procedures
Hydraulic System Checking Procedures
(Hyd #1)

Hydraulic Oil Supply

Reference: Refer to the "Operation and Maintenance Manual".

(Hyd #2)
Suction Filter Clean Up

Reference: Refer to the "Operation and Maintenance Manual".

(Hyd #3) Check Of Pilot Pressure At Main Control Valve Inlet

Main Control Valve Compartment (Viewed From Front Of Machine)

(1) Pilot line (boom RAISE). (2) Pilot line (bucket CLOSE). (3) Pilot line (REVERSE RIGHT travel). (4) Pilot line (REVERSE
LEFT travel). (5) Pilot line (swing LEFT). (6) Pilot line (stick IN).

Main Control Valves (Viewed From The Rear Of The Machine)

(7) Pilot line (stick OUT). (8) Pilot line (swing RIGHT). (9) Pilot line (FORWARD LEFT travel). (10) Pilot line (FORWARD
RIGHT travel). (11) Pilot line (bucket OPEN). (12) Pilot line (boom LOWER).

1. To check the pilot pressure at each inlet port of the main control valves, connect a tee
between each pilot line and its control valve.

2. Attach a 4900 kPa (700 psi) pressure gauge to the tee.

3. With the hydraulic activation control lever in the UNLOCKED position, operate the pilot
control lever for each function.

(Hyd #4) Swing Motor Performance Problem (Measurement Of Case Drain

Oil)

Swing Motor Compartment

(1) Case drain line. (2) Tee. (3) Case drain line.

Main Control Valve Compartment

(4) Elbow. (5) Pilot line.
To check the swing motor performance, measure the amount of swing motor case drain oil as
follows:

1. Stop the engine. Release the pressure in the hydraulic system. See the section in this module,
"Release Of Pressure In The Hydraulic System".

2. Disconnect case drain line (1) from tee (2) on the swing motor.

3. Install a plug (13/16- 16UN) in the end of case drain line (1) and a cap (13/16- 16UN) in the
open end of tee (2).

4. Disconnect case drain line (3) from the swivel. Put the open end of case drain line (2) into a
suitable measuring container.

5. Install a cap (13/16- 16UN) in the open port of the swivel.

6. Engage the swing parking brake as follows;

a. Disconnect pilot line (5) from elbow (4). Leave the end of pilot line (5) open the the air.

b. Install a cap (11/16- 16HD)(6V9829) on elbow (4).

7. Start and run the engine at high idle speed of 2010 ± 50 rpm with the power mode selector
switch at Mode III position.

NOTE: The maximum acceptable case drain oil with a swing relief pressure setting of 29 400 ±
980 kPa (4250 ± 140 psi) must be:

For a New swing motor ... 30 liter/min (7.9 U.S. gpm)

For a Rebuilt swing motor ... 35 liter/min (9.2 U.S. gpm)

(Hyd #5) Travel Motor Performance Problem (Measurement Of Case Drain)

Travel Motor
(1) Connector. (2) Drain hose.

To check the travel motor performance, measure the amount of case drain oil as follows:

1. Disconnect drain hose (2) from connector (1). Install a plug in the open end of drain hose (2).

2. Connect one end of the vinyl hose to connector (1) and put the other end of the vinyl hose
into a suitable measuring container.

3. With the track blocked, operate the travel control for one minute.

4. Measure the amount of case drain oil.

5. Remove the track block, and move the machine forward to place the travel motor barrel in a
new position.

6. Repeat steps 1 through 4.

NOTE: The maximum acceptable case drain oil at each measuring point with a main relief
pressure of 34 300 ± 490 kPa (5000 ± 72 psi) must be:

For a New travel motor ... 15 liter/min (4.0 U.S. gpm)

For a Rebuilt travel motor ... 18 liter/min (4.8 U.S. gpm)

Testing And Adjusting

Introduction

Hydraulic oil pressure can remain in the hydraulic systems

on this machine after the engine and pump have been
stopped. Serious injury can be caused if this pressure is not
released before any service is done on the hydraulic
systems. To prevent possible injury, refer to section, Release
 Of Pressure In The Hydraulic System, before any fitting, hose
or component is loosened, tightened, removed or adjusted.

When possible, the bucket must always be lowered to the

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

Always move the machine to a location away from the travel

of other machines. Be sure that other personnel are not near
the machine when the engine is running and tests or
adjustments are being made.

During diagnosis of the hydraulic system, remember that correct oil temperature, flow, and
pressure are necessary for correct operation. Pump output (oil flow) is a function of engine
speed (rpm). Oil pressure is caused by resistance to the flow of oil.

Visual Checks
A visual inspection of the system is the first step when troubleshooting a problem. Make the
inspection with the engine stopped and the implements lowered to the ground.

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

2. Remove the filter element and check it for material that would give an indication of damage
to a component.

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

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

Checks During Operation

The checks during operation can be used to find leakage in the system. They can also be used
to find a valve, pump, motor, or cylinder that is not working correctly. The speed of rod
movement or the torque on a motor can be used to check the condition of the cylinders,
motors, and pumps.

Operational Tests
NOTE: For specifications given in "Operational Tests", a "NEW" specification is the
performance that can be expected for a new machine. A "REBUILD" specification is the
performance target to use after rebuilding the components of a system. A machine that
performs beyond "SERVICE LIMIT" specifications should be checked for improper
maintenance or adjustment, component wear, or failure.

Specifications given in charts for a machine equipped with 5900 mm (19 ft 4 in) boom, 2950
mm (9 ft 8 in) stick, and SAE 1.0 m3 (1-1/4 yd3) bucket.

NOTE: The power mode selector switch must be placed at Mode III position, unless otherwise
specified, during tests.

Operational Test Preparations

1. Engine speed:

Excavator with no load at high idle, 2010 ± 50 rpm

2. Hydraulic oil temperature: 55 ± 5°C (131 ± 9°F)

NOTE: Fully move the stick in and out several times until the normal hydraulic oil
temperature is reached.
 3. Relief valve pressure settings are set according to specification.

Reference: Make reference to the section in this module "Relief Valves", "Specifications".

Travel Test On Level Ground

Test Preparation:

1. Set engine speed and increase the hydraulic oil to normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft) long.

3. Draw a 25 m (82.5 ft) straight line on travel test ground as a reference line.

4. Position the machine so that one track is in line (parallel) with the reference line. Put the
machine in the travel test position as shown in the illustration.

5. The bucket must be empty.

Test Procedure:

1. Start the engine and place the power mode selector switch in mode III position. Place the
engine speed dial at position "10" and the travel speed switch in HIGH (rabbit) position. Move
the machine by operating both travel levers at the same time.
2. The first 5 m (16.5 ft) are for a preliminary run. Measure the time required for the machine
to travel the remaining 20 m (66 ft) in each direction (FORWARD and REVERSE).

3. Measure the travel deviation from the reference line.

4. Repeat the above procedure with the travel speed switch in LOW (turtle) position.

NOTE: The following chart represents the time (in seconds) it should take to complete the 20 m
(66 ft) test run:

NOTE: The following chart represents the travel deviation from the reference line:

Travel On Level Ground (Optional Test)

NOTE: If suitable ground (as stated in Step No. 2 in "Test Preparation" for "Travel On Level
Ground") cannot be found, the following test should be done as a substitute.

Test Preparation:

1. Set engine speed and increase the hydraulic oil to normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground.

3. Raise a track for the test as shown in the illustration.

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

Test Procedure:

1. Start the engine and place the power mode selector switch in power Mode III position. Run
the raised track with the engine speed dial at position "10" (high idle) and the travel speed
switch in HIGH (rabbit) position.

2. Measure the time required for the track to make three complete turns (revolutions) in each
direction (FORWARD and REVERSE).

3. Repeat the above procedure with the travel speed switch in LOW (turtle) position.
Drift On Slope

Measuring the amount of drift of the machine on a slope will determine if there is a need to
check the travel brake.

Test Preparation:

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

2. Put the implements in the position shown in the illustration.

3. Bucket should be empty.

Test Procedure:
1. Put marks on both track and ground to indicate its relative position to the slope.

2. Stop the engine and time three minutes (using a stopwatch).

3. Measure (with a scale) the distance the tracks have moved on the slope.

Swing Speed And Over Swing (On Level Ground)

Measuring the swing speed and over swing of the machine will determine if there is a need to
check the swing motor and/or anti-reaction valve.

Test Preparation:

1. Set engine speed and increase the hydraulic oil to normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground as shown in the illustration.

3. Put marks on both inner and outer races of the swing bearing to indicate relation of two
positions.

4. The bucket should be empty.

Test Procedure (Over Swing):

1. Start the engine and place the power mode selector switch in power Mode III position. Place
the engine speed dial at position "10" (high idle).

2. Move the swing control lever to the RIGHT or LEFT until the machine completes a 180°
swing operation. Return the swing control lever to the NEUTRAL position at the end of the 180°
swing operation and measure the amount of over swing by measuring the distance between
the marks on the swing bearing.

NOTE: Use a reference point that is visible from the operator's seat as a indicator of when to
stop the 180° rotation.
Test Procedure (Speed):

1. Move the swing control lever to the LEFT or RIGHT and measure the time it takes to
complete a 180° swing operation.

Swing Speed And Drift (On A Slope)

Measuring the swing speed on a slope will determine if there is a need to check the swing
motor and/or anti-reaction valve. Measuring the swing drift on a slope will determine if there
is a need to check the swing parking brake.

Test Preparation:

1. Place the machine on a 12° slope.

2. Place the implements at maximum reach and fill the bucket with soil. The bucket should be
positioned above the ground to clear any obstructions.

Test Procedure (Speed):

1. Stop the machine on a slope of 12°. Place the upper structure at a 90° angle to the lower
structure as shown in the illustration.

2. Measure the time needed to swing the upper structure 90° counterclockwise. Do the same
for a 90° swing clockwise.
Test Procedure (Drift):

1. Stop the machine on a slope of 12°.

2. Place the upper structure at a 90° angle to the tracks as shown in the illustration.

3. Put marks on the inner and outer races of the swing bearing.

4. Stop the engine.

5. Leave the machine in this position for three minutes, and measure swing drift on the
circumference of the swing bearing.

6. Rotate the upper structure 180° from the original position as described in Step 1.

7. Repeat Steps 2 through 5.

Cylinder Drift

Test Preparation:

1. Set engine speed and increase the hydraulic oil to normal operating temperature.

Reference: Make reference to the section "Operation Tests Preparation"

2. Place the machine on level ground as shown in the illustration.

3. Fill the bucket with soil.

Test Procedure (For Boom And Stick Cylinders):

1. Fully extend the bucket cylinder.

2. Fully retract the stick cylinder.

3. Raise the boom until its upper surface becomes parallel to the ground.

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

5. Stop the engine.

6. Leave the machine in this position for three minutes, then measure each cylinder's length
from pin to pin for drift.

Test Procedure (For Bucket Cylinder):

1. Fully extend the bucket cylinder.

2. Raise the boom high enough until the stick is perpendicular to the ground.

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

4. Stop the engine.

5. Leave the machine in this position for three minutes, then measure each cylinder's length
from pin to pin for drift.
Cylinder Operating Speed

Test Preparation:

1. Place the machine on level ground.

2. Bucket must be empty.

Test Procedure (Boom Cylinders):

Fully retract bucket and stick cylinders.

Extension test;

Measure the time required for the boom cylinders to reach full extension position starting
with the bucket on the ground.
Retraction test;

Measure the time required for the bucket to come in contact with the ground from the full
extension position of the boom cylinders.

Test Procedure (Stick Cylinder):

Position the upper surface of the boom parallel to the ground and fully extend the bucket
cylinder.

Extension test;

Measure the time required for the stick cylinder to reach full extension position from full
retraction position.
Retraction test;

Measure the time required for the stick cylinder to reach full retraction position from full
extension position.

Test Procedure (Bucket Cylinder):

Position the upper surface of the boom parallel and the stick perpendicular to the ground.

Extension test;

Measure the time required for the bucket cylinder to reach full extension position from full
retraction position.
Retraction test;

Measure the time required for the bucket cylinder to reach full retraction position from full
extension position.

Release Of Pressure In The Hydraulic

System
Release the pressure in the implement hydraulic circuits (boom, stick, and bucket) before any
hydraulic lines or components are disconnected or removed.

1. Fully retract the stick cylinder rod.

2. Adjust the position of the bucket so that it will be flat on the ground when the boom is
lowered.

3. Lower the boom until the bucket is flat on the ground.

4. Stop the engine and put the hydraulic activation control lever in the UNLOCK position.

5. Move the control levers for boom, stick, and swing to all full stroke positions. This will
release any pressure that might be present in the pilot system.

6. Slowly loosen the pressure cap on the hydraulic tank and remove to release the pressure.

7. Reinstall and tighten the pressure cap on the hydraulic tank.

8. The pressure in the hydraulic system has been released and lines and components can be
removed.
Release Of Air From Main Pumps
When the main pumps have been serviced or the hydraulic oil have been replaced, remove air
from the hydraulic system as follows:

NOTICE
No attempt should be made to start the engine until the
main pumps have been filled with hydraulic oil, or serious
damage can be caused to hydraulic components.

Pump Compartment
(1) Air vent plug.

1. With the engine stopped, remove air vent plug (1) on the top of the main pump. Leave air
vent plug (1) off for several minutes until the main pumps are fill with hydraulic oil. After the
pumps fill with oil, install and tighten air vent plug (1) and start the engine in low idle. Fully
raise the boom and hold it in this position.

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

3. Slowly loosen air vent plug (1) several turns until the oil flows out of the plug opening. This
is an indication that the air has completely been released from the pumps.

4. Tighten air vent plug to the specified torque.

Pressure Adjustment
Specifications
NOTE: A new or rebuilt machine must perform according to NEW or REBUILD specifications. A
machine that performs beyond SERVICE LIMIT specifications must be checked for improper
adjustment, wear, or damage of relief valves or pumps.
Adjustment Procedures
NOTE: Values given above are approximate. Use a pressure gauge for adjustment.

Relief Valve Adjustment Preparation

Pump Compartment
(1) Tap (power shift pressure). (2) Tap (upper pump). (3) Tap (lower pump).

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

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".

3. Connect a 49 000 kPa (7100 psi) pressure gauge to either the main pump tap (2) or tap (3).

4. Connect a 4900 kPa (700 psi) pressure gauge to tap (1).

5. Start the engine and move the stick IN and OUT to its full travel position. Do this operation
several times until the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).
6. Place the power mode selector switch in Mode III position.

7. Place the engine speed dial at position "10". Check that engine speed under no load is at 2010
± 50 rpm with AEC switch in the OFF position. (Read rpm 3 seconds after the speed dial switch
has been placed in position "10".)

NOTE: See the, "Operation And Maintenance Manual" for the specified engine rpm for dial
position "10".

NOTE: Normal operations (see characteristic curve) of the engine and pumps are necessary for
the pressure adjustment. If the results of the pressure adjustment are not correct, then the
engine and pump characteristic curve needs to be checked.

Temporary Setting Of The Main Relief Valve Pressure

NOTE: The purpose for "Temporary Setting Of The Main Relief Pressure" is done so implement
line relief valves and travel relief valves can be adjusted.

Top Of Main Control Valves

(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.

1. Slowly move the bucket control lever to the bucket open position (full cylinder rod
retraction).

2. Check to be sure the main relief valve pressure setting is 31 400 ± 490 kPa (4550 ± 72 psi).

NOTE: Always make final pressure adjustments on pressure rise.

3. Loosen locknut (5) and turn plunger (4) clockwise until it bottoms out. Tighten locknut (5).

4. Loosen locknut (7) and turn adjuster (6) clockwise a quarter turn. Tighten locknut (7).

Adjustment Of Line Relief Valve Pressure

Preparation

1. Temporary set the main relief valve. See the section, "Temporary Setting Of The Main Relief
Valve Pressure".
2. Start the service program "Calibration Mode" and keep the power shift pressure constant at
2550 kPa (370 psi). Read the pressure gauge attached at tap (1) to monitor the power shift
pressure.

NOTE: For further information of "Calibration Mode", see the manual "Engine And Pump
Electronic Control System, System Operation, Testing And Adjusting".

NOTE: During line relief adjustment, do not turn the engine OFF to prevent a change in power
shift pressure.

3. Use the pressure gauge at tap (2) to read the line relief pressure for boom and bucket
circuits. Use the pressure gauge at tap (3) to read the line relief pressure for stick circuit. For
line relief pressure settings for the implement circuits see the section, "Pressure Adjustment,
Specifications".

NOTE: After adjustment of the line relief valves, return the main relief pressure to its normal
setting. See the section, "Main Relief Valve Adjustment".

Main Control Valve Compartment (Viewed From Front Of Machine)

(9) Line relief valve (bucket cylinder head end). (10) Line relief valve (stick cylinder head end).

NOTE: Rod end line relief valves of boom, stick, and bucket are located under the main control
valves.

Right Front Of Swing Motor

(11) Boom drift reduction valve. (12) Line relief valve (boom cylinder head end).
Line Relief Valve (typical all cylinders)
(13) Locknut. (14) Screw.

Adjustment (Stick Cylinder)

1. To adjust the pressure in the stick cylinder rod end, move the stick control lever to full stick
OUT (rod retracted) position. Check the pressure in the stick cylinder rod end at tap (3).

2. Return the stick control lever to the NEUTRAL position. Loosen locknut (13) and turn screw
(14) until line relief valve pressure at tap (3) reads 33 800 ± 1470 kPa (4900 ± 215 psi). Turning
screw (14) clockwise increases the pressure and turning screw (14) counterclockwise
decreases the pressure.

3. To adjust the pressure in the stick cylinder head end, move the stick control lever to full
stick IN (rod extended) position. Check the pressure at tap (3).

4. Return the stick control lever to the NEUTRAL position. Adjust the line relief valve pressure
in the same manner as the stick rod end.

NOTE: Always make final pressure adjustment on pressure rise.

Adjustment (Bucket Cylinder)

1. To adjust the pressure in the bucket cylinder head end, move the bucket control lever to full
bucket CLOSE (rod extended) position. Check the pressure in the bucket cylinder head end at
tap (2).

2. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve
pressure in the same manner as described for the stick cylinder.

3. To adjust the pressure in the bucket cylinder rod end, move the bucket control lever to full
bucket OPEN (rod retracted) position. Check the pressure at tap (2).
4. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve
pressure to 33 800 ± 1470 kPa (4900 ± 215 psi) using the same procedure as that described for
the stick cylinder.

NOTE: Always make final pressure adjustment on pressure rise.

Adjustment (Boom Cylinder)

1. To adjust the pressure in the boom cylinder head end, move the boom control lever to full
boom RAISE (rod extended) position. Check the pressure in the boom cylinder head end at tap
(2).

2. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve
pressure in the same manner as described for the stick cylinder.

3. To adjust the pressure in the boom cylinder rod end, move the boom control lever to full
boom DOWN (rod retracted) position. Check the pressure at tap (2).

4. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve pressure
to 33 800 ± 1470 kPa (4900 ± 215 psi) using the same procedure as that described for the stick
cylinder.

NOTE: Always make final pressure adjustment on pressure rise.

NOTE: If an appropriate location is not available for full retraction of the boom cylinder,
reverse the line relief valves of the head end and rod end by switching the valves. Adjust the
pressure of the line relief valve now attached in the head end. Once adjusted, return the
respective relief valves to their original positions and cancel the function of the service
program "Calibration Mode". Refer to the manual, "Engine And Pump Electronic Control
System, System Operation, Testing And Adjusting".

NOTE: After adjustment of the line relief valves, return the main relief pressure to its normal
setting. See the section, "Main Relief Valve Adjustment".

Travel Motor Crossover Relief Valve Adjustment

Sprocket (Left Track)

(16) Sprocket. (17) Stopper.
Travel Brake Valve (Left Track)
(18) Screw. (19) Locknut. (20) Crossover relief valve (forward left travel). (21) Crossover relief valve (reverse left
travel).

Pump Compartment
(1) Tap (power shift pressure). (2) Tap (upper pump). (3) Tap (lower pump).

Preparation

1. Start Service Program "Calibration Mode" and maintain power shift pressure at 2550 kPa
(370 psi). Read the pressure gauge at tap (1) for the power shift pressure settings.

NOTE: During this test, to prevent a change in power shift pressure do not turn the engine
start switch to OFF position.

NOTE: For further information of "Calibration Mode", see the manual "Engine And Pump
Electronic Control System, System Operation, Testing And Adjusting".

2. Block forward left travel, by putting stopper (17) in position on the gear of sprocket (16), as
shown above.

Adjustment Procedure

1. Slowly move the left travel control lever to full FORWARD position and check the pressure of
crossover relief valve (20) at tap (3).

2. Return the control lever to the NEUTRAL position and adjust relief valve pressure. To adjust
crossover relief valve (20), loosen locknut (19) and turn screw (18) until the pressure gauge at
tap (3) reads 36 800 ± 1470 kPa (5350 ± 215 psi).

3. Tighten locknut (19) to a torque of 70 ± 7 N·m (50 ± 5 lb ft).

NOTE: Always make final pressure adjustments on pressure rise.

4. Position stopper (17) to block reverse left travel.

5. Slowly move the left travel control lever to full REVERSE position and check the pressure of
crossover relief valve (21) at tap (3). Adjust the pressure of crossover relief valve (21) in the
same manner as described for crossover relief valve (20).

6. Adjust the pressure of crossover relief valves of right travel motor in the same manner as
described for the left travel motor. Use the pressure gauge at tap (2) to read the pressure.

7. After completion of adjustment, stop the function of the service program "Calibration Mode".
Refer to the manual, "Engine And Pump Electronic Control System, System Operation, Testing
And Adjusting".

Swing Motor Relief Valve Pressure Adjustment

Swing Motor Compartment

(22) Relief valve (left swing). (23) Relief valve (right swing). (24) Locknut. (25) Plug.

Main Control Valve Compartment

(26) Elbow. (27) Pilot line.

Preparation

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

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".

3. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (3).

4. Engage the swing parking brake as follows;

a. Disconnect pilot line (27) from elbow (26).

b. Install a cap (11/16-16HD) (6V9829) on elbow (26). Leave the end of pilot line (27) open to the
air.

5. Start the engine and place the engine speed dial at position "10" with the power mode
selector switch at Mode III position.

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

Adjustment Procedure

1. Slowly move the swing control lever for a full RIGHT swing operation and check the
pressure of relief valve (23).

2. Return the swing control lever to the NEUTRAL position. Loosen locknut (24) and turn plug
(25) until line relief valve pressure at tap (3) reads 27 500 ± 980 kPa (4000 ± 140 psi). Turning
plug (25) clockwise increases the pressure and turning plug (25) counterclockwise decreases
the pressure.

NOTE: Check to be sure that the swing parking brake is correctly being engaged while the
swing control is activated.

3. To adjust the relief pressure for left swing, slowly move the control lever to a full LEFT
swing operation and check the pressure of crossover relief valve (22).

4. Return the swing control lever to the NEUTRAL position. Adjust the relief valve pressure in
the same manner as the swing right relief valve.

NOTE: Always make final pressure adjustment on the pressure rise.

5. After adjustment, disengage the swing parking brake as follows;

a. Stop the engine and release the pressure in the hydraulic system.

b. Remove the cap (11/16-16HD)(6V9829) from elbow (26).

c. Connect pilot line (27) to elbow (26).

Main Relief Valve Adjustment

NOTE: Pressure adjustments to the main relief valve should be done by first adjusting the
travel operation of the main relief valve and then adjusting the implement operation of the
main relief valve. Any adjustment to the travel operation of the main relief valve will change
the pressure setting to the implement operation of the main relief valve.

NOTE: Always make final pressure adjustments on pressure rise.

NOTE: During main relief valve pressure adjustment, the power mode switch must be placed
in Mode III position.

Top Of Main Control Valves

(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.

Pump Compartment
(1) Tap (power shift pressure). (2) Tap (upper pump). (3) Tap (lower pump).

Preparation

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

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".

3. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (3).

4. Start the engine and place the engine speed dial at position "10" with the power mode
selector switch at Mode III position.

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

Adjustment Procedure (In Travel Operation)

Sprocket (Left Track)
(16) Sprocket. (17) Stopper.

1. Block forward left travel by putting stopper (17) in position on the gear of sprocket (16).

2. Slowly move the left travel control lever to full FORWARD position and check main relief
valve pressure at tap (3).

3. Return the control lever to the NEUTRAL position.

4. Loosen locknut (7) and turn adjuster (6) until the pressure gauge at tap (3) reads 34 300 ±
490 kPa (5000 ± 72 psi). Tighten locknut (7) to a torque of 75 ± 10 N·m (55 ± 7 lb ft).

Reference: Turning adjuster (6) clockwise increases the pressure. Turning adjuster (6)
counterclockwise decreases the pressure.

NOTE: Always make final pressure adjustments on pressure rise.

Adjustment Procedure (Implement Operation)

1. Slowly move the control lever to full bucket OPEN (bucket cylinder full retraction) position
and check the main relief valve pressure at tap (2).

2. Return the control lever to the NEUTRAL position and adjust main relief valve pressure to 31
400 ± 490 kPa (4550 ± 72 psi).

3. To adjust, loosen locknut (5) and turn plunger (4) until the pressure gauge at tap (2) reads 31
400 ± 490 kPa (4550 ± 72 psi). Tighten locknut (5) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).

Reference: Turning plunger (4) clockwise increases the pressure. Turning plunger (4)
counterclockwise decreases the pressure.

NOTE: Always make final pressure adjustments on pressure rise.

Pilot Relief Valve Adjustment

Preparation
Pilot Oil Manifold Compartment
(26) Pilot relief valve. (27) Tap. (28) Screw. (29) Locknut.

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

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".

3. Connect a 49 000 kPa (7100 psi) pressure gauge to either the main pump tap (2) or tap (3).

4. Connect a 4900 kPa (700 psi) pressure gauge to tap (27).

5. Start the engine and move the stick IN and OUT to its full travel position. Do this operation
several times until the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).

6. Place the power mode selector switch in Mode III position.

7. Place the engine speed dial at position "10". Check that engine speed under no load is at
specified rpm with AEC switch in the OFF position. (Read rpm 3 seconds after the speed dial
switch has been placed in position "10".)

NOTE: See the manual, "Operation And Maintenance Manual" for the specified engine rpm for
dial position "10".

NOTE: Normal operations (see characteristic curve) of the engine and pumps are necessary for
the pressure adjustment. If the results of the pressure adjustment are not correct, then the
engine and pump characteristic curve needs to be checked.

Adjustment Procedure

1. Loosen locknut (29) of pilot relief valve (26).

2. Turn screw (28) until the pressure gauge reads 3450 + 200 - 0 kPa (500 + 29 - 0 psi).

Reference: Turning screw (28) clockwise increases the pressure and turning screw (28)
counterclockwise decreases the pressure.

3. Tighten locknut (29) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).

NOTE: Always make final pressure adjustments on pressure rise.

Adjustment Of Automatic Travel Speed Travel Change Valve

Preparation

1. Reset main relief valves. Refer to the section, "Main Relief Valve Adjustment".

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".

Pump Compartment
(1) Tap (lower pump).

3. Install 49 000 kPa (7100 psi) pressure gauge at tap (1) of the lower pump.

Pilot Oil Manifold Compartment

(2) Tap.
4. Install 4900 kPa (700 psi) pressure gauge at tap (2) of pilot oil manifold.

Travel Motor (Left Track)

(3) Hose assembly. (4) Tee. (5) Signal line (two speed travel). (6) Elbow (two speed travel port).

5. Disconnect signal line (5) from the travel motor. Install tee (4) (8T8902) on elbow (6) that the
signal line was removed from and connect signal line (5) to tee (4). Attach nipple (6V3965) and
O-ring seal (3J1907) to tee and install 4900 kPa (700 psi) pressure gauge to the nipple with test
hose assembly (6V3014) and coupler assembly (6V4143).

6. Start the engine and raise the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).

7. Place the power mode selector switch in power Mode III position and maintain the
maximum no load speed of 2010 ± 50 rpm with AEC switch OFF.

Sprocket (Left Track)

(7) Sprocket. (8) Stopper.

8. Block the forward left travel by putting stopper (8) in position on the gear of sprocket (7), as
shown above.

9. Place the travel speed control switch in HIGH (rabbit) position.

10. The pressure gauge at tap (2) should read 3450 kPa (500 psi).

Adjustment Procedure
Pilot Oil Manifold Compartment
(9) Locknut. (10) Screw. (11) Automatic travel speed change valve.

1. While reading the pressure gauges connected to the signal pressure line (5) and at tap (1),
slowly move the left travel control lever/pedal to the FORWARD position. When the pressure at
tap (1) reads 32 400 ± 980 kPa (4700 ± 140 psi), the pressure gauge connected to signal line (5)
should reduce to 0 kPa (0 psi).

NOTE: These pressures indicate that the automatic travel speed change valve has caused the
travel motor to shift to LOW (tortoise) speed.

2. Slowly return the left travel control lever/pedal to the NEUTRAL position.

3. If the pressure gauge connected to signal line (5) does not read 0 kPa (0 psi) at the time the
system pressure at tap (1) reads 32 400 ± 980 kPa (4700 ± 140 psi), then adjust automatic travel
speed change valve (11) as follows:

NOTE: Always make final pressure adjustments on pressure rise.

a. Loosen locknut (9) and turn screw (10) until the pressure gauge connected to line (5) reads 0
kPa (0 psi) when the pressure gauge at tap (1) reads 32 400 ± 980 kPa (4700 ± 140 psi).

b. Tighten locknut (9) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).

NOTE: Turning screw (10) clockwise increases the pressure. Turning screw (10)
counterclockwise decreases the pressure.

4. Repeat Step 1.

5. Slowly move the travel control lever/pedal towards the NEUTRAL position until the pressure
gauge at tap (1) decreases to 18 600 ± 980 kPa (2700 ± 140 psi). Now the pressure gauge
connected to signal line (5) will read 3450 kPa (500 psi).

NOTE: These pressures indicate when the automatic travel speed change valve causes the
travel motor to shift to HIGH (rabbit) speed.

Pump Flow Tests

Controller Compartment
(1) Controller alarm lamp. (2) Controller.

Right Console
(3) Monitor. (4) Monitor panel.

NOTE: Before starting pump flow tests, check the action alarm indicators on controller (2) and
monitor panel (4). If they indicate normal, then perform the operational tests.

NOTE: If operational tests (for example, cycle times) indicates that a slow implement problem
is common to the circuits of one pump, then the problem is most likely in the hydraulic system.
Then perform the "Pump Flow Tests".

NOTE: If the operational tests indicate a implement speed problem common to both pump
circuits, then the engine, fuel, or working altitude may be the problem.

Main Pump Constant Horsepower Control Test

Illustration Of Flow Meter Tool Layout 1 (Hydraulic Horsepower Control Test) (Main Pumps)
(1) Portable Hhydraulic Ttester. (2) O-ring seal. (3) Adapter. (4) O-ring seal. (5) Nipple. (6) Coupler. (7) Coupling. (8)
Sleeve. (9) Hose. (10) Fitting. (11) Plug. (12) O-ring seal. (13) Bolt. (14) Washer. (15) Flange. (16) Adapter. (17) Seal. (18)
Cover. (19) Coupling. (20) O-ring seal. (21) Tee. (22) Delivery line (lower pump). (23) Delivery line (upper pump). (24)
Upper pump. (25) Lower pump. (26) Swing motor. (27) Connector. (28) Makeup line.

Preparation (Upper Pump)

Circuit Diagram For Flow Test (Hydraulic Constant Horsepower Control)(Upper Pump)
(1) Portable hydraulic tester. (15) Flange. (18) Cover. (21) Tee. (22) Delivery line (lower pump). (23) Delivery line
(upper pump). (24) Upper pump. (25) Lower pump. (26) Swing motor. (27) Connector. (28) Makeup line. (29) Main
control valves. (30) Gauge. (31) Gauge. (32) Tap (power shift pressure). (33) Tap (upper pump). (34) Tap (lower pump).
(35) Multitach. (36) Engine.
Swing Motor Compartment
(26) Swing motor. (27) Connector. (28) Makeup line.

Pump Compartment
(23) Delivery line (upper line). (24) Upper pump. (25) Lower pump. (32) Tap (power shift pressure). (33) Tap (upper
pump). (34) Tap (lower pump).

Portable Hydraulic Tester (Flow Meter)

(1) Portable hydraulic tester (flow meter). (35) Multitach. (37) Valve (flow meter).

To prevent personal injury or equipment damage from

failure of the flow meter or associated circuit components
because of blocked pump flow, make sure before starting the
engine that the portable hydraulic tester (flow meter) valve
is fully open (turned counterclockwise).

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

2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".

NOTE: The bolts that retain the guard between the pumps and engine may require loosening
to provide sufficient clearance to install tooling.

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

a. Disconnect delivery line (23) from upper pump (24).

b. Install cover (18), seal (17), flange (15), bolt (13), and washer (14) to the end of delivery line
(23).

c. Disconnect makeup line (28) from connector (27) of swing motor (26).

d. Install tee (21) and O-ring seal (20) to connector (27). Connect makeup line (28) and O-ring
seal (20) to tee (21).

e. Connect portable hydraulic tester (1) between upper pump (24) and tee (21) with two hoses
(9).

f. Install pressure gauge (31) at power shift pressure tap (32). Install pressure gauge (30) at
upper pump tap (33). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure
gauge (30).] Tap (32) is used to measure the power shift pressure. Tap (33) are used to measure
the upper pump and lower pump delivery pressure.

g. Install multitach group (35) on engine (36). This is used to read engine speed.

4. Start the engine and place the power mode selector switch in Mode III position.

5. Place the engine speed dial at position "10" and maintain the maximum no load speed at
2010 ± 50 rpm with the AEC switch OFF. (Read the rpm three seconds elapsed time after the
engine speed dial has been placed in position "10").

6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil
temperature, move the stick IN and OUT its full travel several times.

Preparation (Lower Pump)

Pump Compartment
(22) Delivery line (lower pump). (24) Upper pump. (25) Lower pump. (32) Tap (power shift pressure). (33) Tap (upper
pump). (34) Tap (lower pump).

Perform the same preparation as that described for the upper pump flow test under constant
horsepower control except Step 3. Use the following procedure in replacement for Step 3, for
the lower pump (25).

a. Disconnect delivery line (22) from lower pump (25).

b. Install cover (18), seal (17), flange (15), bolt (13), and washer (14) to the end of delivery line
(22).

c. Disconnect makeup line (28) from connector (27) of swing motor (26).

d. Install tee (21) and O-ring seal (20) to connector (27) of swing motor (26). Connect makeup
line (28) and O-ring seal (20) to tee (21).

e. Connect portable hydraulic tester (1) between lower pump (25) and tee (21) with two hoses
(9).

f. Install pressure gauge (31) at power shift pressure tap (32). Install pressure gauge (30) at
lower pump tap (34). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure
gauge (30).] Tap (32) is used to measure the power shift pressure. Tap (34) is used to measure
the lower pump delivery pressure.

g. Install multitach group (35) on engine (36). This is used to read engine speed.

Test Procedure

NOTE: Perform the upper and lower pump flow tests one at a time.

To prevent personal injury or equipment damage from

failure of the flow meter or associated circuit components
because of blocked pump flow, make sure before starting the
engine that the portable hydraulic tester (flow meter) valve
(1) is fully open (turned counterclockwise).

To prevent personal injury and/or equipment damage from

failed lines or components while the portable hydraulic
tester (flow meter) is returned to the open flow position
after a flow test, slowly open the flow meter valve and
monitor pump flow at the same time to make sure flow
increases. If pump flow does not increase as the flow meter
is opened, shut the engine off and determine what is causing
the pump not to upstroke.

1. With the engine running, start the service program "Calibration Mode" and maintain the
power shift pressure at a constant pressure of 1870 ± 50 kPa (270 ± 7 psi). The power shift
pressure is read at tap (32), using pressure gauge (31).
NOTE: During this test, do not turn the starter switch to the OFF position to prevent any
change in power shift pressure. See the section, "Calibration Mode Stop Procedure".

NOTE: To start service program "Calibration Mode" see the section, "Calibration Mode Start-
up", in the manual, "Engine And Pump Electronic Control System, System Operation, Testing
And Adjusting".

2. Slowly turn valve (37) of portable hydraulic tester (1) clockwise and record pump flow at
each of the following pressure points. Use pressure gauge (30) at tap (33) or (34) for this
pressure reading.

P-Q Characteristic Curve

NOTE: Flow specifications given above are based on an engine speed of 1950 rpm. To get more
accurate test results, each of measurements should be corrected by calculating as follows.

Flow corrected = (Flow measured × 1950) ÷ rpm measured

1. Any flow readings must be done only in upstroke (pressure rise).

2. The pump flow changes approximately 10 liter/min. (2.6 U.S. gpm) for each 100 kPa (14
psi) of power shift pressure.

Negative Flow Control Test

Illustration Of Flow Meter Tool Layout 1 (Negative Flow Control Test) (Main Pumps)
(1) Portable Hydraulic Tester. (2) O-ring seal. (3) Adapter. (4) O-ring seal. (5) Nipple. (6) Coupler. (7) Coupling. (8)
Sleeve. (9) Hose. (10) Fitting. (11) Plug. (12) O-ring seal. (13) Bolt. (14) Washer. (15) Flange. (16) Adapter. (17) Seal. (18)
Cover. (19) Coupling. (20) O-ring seal. (21) Tee. (22) Delivery line (lower pump). (23) Delivery line (upper pump). (24)
Upper pump. (25) Lower pump. (26) Swing motor. (27) Connector. (28) Makeup line.

Preparation (Upper Pump)

Circuit Diagram For Negative Flow Control Test (Upper Pump)
(1) Portable hydraulic tester(flow meter). (15) Flange. (18) Cover. (21) Tee. (22) Delivery line (lower pump). (23)
Delivery line (upper pump). (24) Upper pump. (25) Lower pump. (26) Swing motor. (27) Connector. (28) Makeup line.
(29) Main control valves. (30) Negative flow control line (upper pump). (31) Gauge. (32) Tap (upper pump). (34) Tap.
(35) Tee. (36) Hose assembly. (37) Plug. (38) Gauge. (39) Negative flow control line (lower pump). (40) Tap (lower
pump). (41) Multitach. (42) Engine.

Pump Compartment
(23) Delivery line (upper pump). (24) Upper pump. (25) Lower pump. (30) Negative flow control line (upper pump).
(32) Tap (upper pump).

Pilot Manifold Compartment

(33) Pilot oil manifold. (34) Tap. (43) Pilot relief valve.

Swing Motor Compartment

(26) Swing motor. (27) Connector. (28) Makeup line.

Portable Hydraulic Tester (flow meter)

(1) Portable hydraulic tester (flow meter). (41) Multitach. (44) Valve.
Illustration Of Tool Layout 2 (Negative Flow Control Test) (Main Pump)
(12) O-ring seal. (24) Upper pump. (25) Lower pump. (30) Negative flow control line (upper pump). (33) Pilot oil
manifold. (34) Tap. (38) Gauge. (39) Negative flow control line (lower pump). (45) Tee. (46) Plug. (47) Hose assembly.
(48) Nipple. (49) O-ring seal. (50) Cap. (51) Coupler assembly.

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

2. Release the pressure in the hydraulic system. See the section in this module "Release Of
Pressure In The Hydraulic System".

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

a. Disconnect delivery line (23) from upper pump (24).

b. Install cover (18), O-ring seal (17), flange (15), bolt (13), and washer (14) to the end of
delivery line (23).

c. Disconnect makeup line (28) from connector (27) of swing motor (26).
d. Install tee (21) and O-ring seal (20) to connector (27). Connect makeup line (28) and O-ring
seal (20) to tee (21).

e. Connect portable hydraulic tester (1) between upper pump (24) and tee (21) with two hoses
(9).

f. Remove negative flow control line (30) from port of upper pump (24) and install plug (46)
and O-ring seal (49) in open end of negative flow control line (30).

g. Connect two tees (45) together using and O-ring seal (49). Install one end of the tees to
negative flow control line (30) port of upper pump (24). Install nipple (48) and O-ring seal (12)
in each tee (45). Connect test hose assembly [thread size: 11/16-16UN, 1 m (3.3 ft) long](47) and
two coupler assemblies (51) between nipple (48) on one tee and tap (34) of pilot oil manifold
(33).

h. Install 4900 kPa (700 psi) pressure gauge (38) to nipple (48) on the second tee. Install cap (50)
and O-ring seal (49) on the open end of second tee (45). Install pressure gauge (31) at upper
pump tap (32). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge
(31)]. Gauge (38) is used to measure the negative control flow. Gauge (31) is used to measure
the upper pump or lower pump delivery pressure.

i. Install multitach group (41) on engine (42). This is used to read engine speed.

4. Start the engine and place the power mode selector switch in Mode III position.

5. Place the engine speed dial at position "10" and maintain the maximum no load speed at
2050 ± 50 rpm with the AEC switch OFF. (Read the rpm three seconds elapsed time after the
engine speed dial has been placed in position "10").

6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil
temperature, move the stick IN and OUT its full travel several times.

Preparation (Lower Pump)

Pump Compartment
(22) Delivery line (lower pump). (24) Upper pump. (25) Lower pump. (39) Negative flow control line (lower pump).
(40) Tap (lower pump).
Perform the same preparation as that described for the upper pump negative pump flow
control test except Step 3. Use the following procedure in replacement for Step 3, for the lower
pump (25).

a. Disconnect delivery line (22) from lower pump (25).

b. Install cover (18), O-ring seal (17), flange (15), bolt (13), and washer (14) to the end of
delivery line (22).

c. Disconnect makeup line (28) from connector (27) of swing motor (26).

d. Install tee (21) and O-ring seal (20) to connector (27). Connect makeup line (28) and O-ring
seal (20) to tee (21).

e. Connect portable hydraulic tester (1) between upper pump (25) and tee (21) with two hoses
(9).

f. Remove negative flow control line (39) from port of lower pump (25) and install plug (46)
and O-ring seal (49) in open end of negative flow control line (39).

g. Connect two tees (45) together using and O-ring seal (49). Install one end of the tees to
negative flow control line (39) port of lower pump (25). Install nipple (48) and O-ring seal (12)
in each tee (45). Connect test hose assembly [thread size: 11/16-16UN, 1 m (3.3 ft) long](47) and
two coupler assemblies (51) between nipple (48) on one tee and tap (34) of pilot oil manifold
(33).

h. Install 4900 kPa (700 psi) pressure gauge (38) to nipple (48) on the second tee. Install cap (50)
and O-ring seal (49) on the open end of second tee (45). Install pressure gauge (31) at lower
pump tap (40). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge
(31)]. Gauge (38) is used to measure the negative control flow. Gauge (31) is used to measure
the upper pump or lower pump delivery pressure.

i. Install multitach group (41) on engine (42). This is used to read engine speed.

Test Procedure

NOTE: Perform the upper and lower pump negative flow control tests one at a time.

To prevent personal injury or equipment damage from

failure of the portable hydraulic tester (flow meter) or
associated circuit components because of blocked pump
flow, make sure before starting the engine that the flow
meter valve (44) is fully open (turned counterclockwise).
 To prevent personal injury and/or equipment damage from
failed lines or components while the portable hydraulic
tester (flow meter) is returned to the open flow position
after a flow test, slowly open the flow meter valve and
monitor pump flow at the same time to make sure flow
increases. If pump flow does not increase as the flow meter
is opened, shut the engine off and determine what is causing
the pump not to upstroke.

1. Place the power mode selector switch in the Mode III position.

2. Negative flow control test for the upper and lower pumps must be done one at a time.

3. Slowly turn valve (44) of portable hydraulic tester (1) clockwise until the pump delivery
pressure setting is 6850 kPa (1000 psi).

4. Adjust pilot relief valve (43) of pilot oil manifold (33) until pressure gauge (38) connected to
tee (35) reads 2250 kPa (325 psi).

5. Record the negative control flow at the following pressure point.

P-Q Characteristic Curve [Negative Flow Control at 6850 kPa
(1000 psi) Pump Delivery Pressure]
NOTE: Flow specifications given above are based on an engine speed of 1950 rpm. To get more
accurate test results, measured flow should be corrected by calculating as follows:

Flow corrected = (Flow measured × 1950) ÷ rpm measured

NOTE: Flow measurements must be taken only in pressure rise.

Pump Flow Adjustment

Pump Output Flow Adjustment

Pump Compartment
(38) Locknut. (39) Setscrew. (40) Locknut. (41) Setscrew.

Output flow adjustment procedure for the upper and lower pumps are the same. Use locknut
(38) and setscrew (39) for the upper pump adjustment and locknut (40) and setscrew (41) for
the lower pump adjustment.

1. Loosen locknut (38).

2. Turn setscrew (39) until adjusted to the correct specification.

Turning setscrew (39) clockwise increases the flow rate. Turning setscrew (39)
counterclockwise decreases the flow rate by the same amount as shown in the clockwise
rotation. A quarter turn of setscrew (39) changes the flow rate as follows;

a. Approximately 19 liter/min (5.0 U.S. gpm) at a system pressure of 15 700 kPa (2300 psi) or 19
600 kPa (2850 psi) where the first stage spring in the pump regulator activates.

b. Approximately 7 liter/min (1.9 U.S. gpm) at a system pressure of 24 500 kPa (3550 psi) or 34
300 kPa (5000 psi) where the second stage spring in the pump regulator activates.

3. Tighten locknut (38) to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

4. Perform the same procedure for the lower pump as that described for the upper pump
output flow adjustment except use locknut (40) and setscrew (41).

Maximum Pump Flow Adjustment

Pump Compartment
(42) Locknut. (43) Setscrew. (44) Setscrew. (45) Locknut.

Maximum pump flow adjustment procedure for the upper and lower pumps are the same. Use
locknut (42) and setscrew (43) for the upper pump adjustment and locknut (45) and setscrew
(44) for the lower pump adjustment.

1. Loosen locknut (42).

2. Turn setscrew (43) until adjusted to the correct specification.

Turning setscrew (43) clockwise decreases the flow rate. Turning setscrew (43)
counterclockwise increases the flow rate by the same amount as shown in the clockwise
rotation. A quarter turn of setscrew (43) changes the flow rate by approximately 1.5 liter/min
(0.4 U.S. gpm).

3. Tighten locknut (42) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

4. Perform the same procedure for the lower pump as that described for the upper pump
maximum pump flow adjustment except use locknut (45) and setscrew (44).

Negative Flow Control Adjustment

Pump Compartment
(45) Setscrew. (46) Locknut. (47) Setscrew. (48) Locknut.

Negative flow control adjustment procedure for the front and rear pumps are the same.

1. Loosen locknut (46).

2. Turn setscrew (45) until adjusted to the correct specification.

Turning setscrew (45) clockwise decreases the flow rate. Turning setscrew (45)
counterclockwise increases the flow rate by the same amount as shown in the clockwise
rotation. A quarter turn of setscrew (45) changes the flow rate by approximately 5 liter/min
(1.3 U.S. gpm) at a system pressure of 2250 kPa (325 psi).

3. Tighten locknut (46) to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

4. Perform the same procedure for the lower pump as that described for the upper pump
maximum pump flow adjustment except use locknut (48) and setscrew (47).

Copyright 1993 - 2020 Caterpillar Inc.

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