318b pump flow test

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Previous Screen Product: EXCAVATOR

Model: 317 EXCAVATOR 4MM00269

Configuration: 317 & 317N Excavators 4MM00001-UP (MACHINE) POWERED BY 3054 Engine

Testing and Adjusting 317 & 317N EXCAVATORS HYDRAULIC SYSTEMS Media Number -SENR6296-01 Publication Date -04/04/1996 Date Updated -12/10/2001

Testing And Adjusting

IntroductionThis manual contains information on the troubleshooting procedures of the hydraulic systems in the 317 excavators. For troubleshooting the engine components, refer to the module Systems Operation, Testing And Adjusting, Basic Engine Components 3054 Engine, SENR5816.

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" Form SENR6155

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.

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Operational Tests

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

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

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 ChecksA visual inspection of the system is the first step when troubleshooting a problem. Make the inspection with the engine off and the implements lowered to the ground.

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

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

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

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



Checks During OperationThe 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 TestsNOTE: 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 5100 mm (16 ft 9 in) boom, 2600 mm (8 ft 6 in) stick, and SAE 0.65 m3 (7/8 yd3) bucket.

NOTE: The power mode selector switch must be placed at MODE III position and the work mode selector switch be in BOOM PRIORITY MODE position, unless otherwise specified, during tests.

Operational Test Preparations

1. Verify engine speed:

Excavator with no load at high idle, 2180 ± 80 rpm



2. Increase hydraulic oil temperature to: 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. Insure relief valve pressure settings are set according to specification.

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

Straight Travel Test

Determining if there is a deviation to the right or left during straight travel can identify a problem with the travel motors or main pumps.

Test Preparation:



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

3. Measure the travel deviation from the reference line.

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

NOTE: If the travel deviation from the reference line is beyond the specification then the travel motors and main pumps may need adjustment.



Component Test:

To determine if the travel motors need adjustment do the following procedure:


2. The first 5 m (16.5 ft) are for a preliminary run.

3. While in straight travel extend the bucket cylinder.

If the forward travel no longer drifts to one side the problem is with the travel pumps, motors or swivel. If the machine continues to drift while extending the bucket cylinder then check the adjustment of the main pumps, swivel, or control valves.

Travel Test On Level Ground

Test 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:


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:

Travel Speed (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:



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 A Slope

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

Test Preparation:

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

2. Put the implements in the position 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:



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

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3. Put two marks, one above the other 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 positions until the machine completes a 360° swing operation. Return the swing control lever to the NEUTRAL position at the end of the 360° swing operation and measure the amount of over swing by measuring the distance between the marks on the swing bearing.

NOTE: Use a reference point that is visible from the operator's seat as a indicator of when to stop the 360° rotation.



Test Procedure (Speed):

Move the swing control lever to the LEFT or RIGHT positions 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:





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 the boom and stick 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 the bucket cylinder's length from pin to pin.

4. Stop the engine.

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

Cylinder Operating Speed

Test Preparation:

1. Place the machine on level ground.



2. Bucket must be empty.

Test Procedure (Boom Cylinders):

1. 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):

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

Extension test;

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



Retraction test;

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

Test Procedure (Bucket Cylinder):

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

Extension test;

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

Retraction test;

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



Control Valve Shift Pressure Test

Introduction

The control valves spools must shift at the proper pilot supply pressure. Proper shifting prevents interaction between the main control valves, the stick II and boom II valves, insures controllability, and makes certain the main control valve spool is shifting completely.

This test provides a means for checking the main control valve for the correct shift actuation pressures.

Check control valve shifting pressure.

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

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

Main Control Valve (1) Stick II control valve. (2) Bucket control valve. (3) Boom I control valve. (4) Attachment control valve. (5) Right



travel control valve. (6) Left travel control valve. (7) Swing control valve. (8) Stick I control valve. (9) Boom II control valve.

c. Install a swivel tee fitting into the pilot signal line of the circuit being tested.

d. Connect a 4000 kPa (580 psi) gauge to the tee.

Pump Compartment (10) Tap (rear pump). (11) Tap (front pump).

e. Install 60 000 kPa (8700 psi) gauges at tap (10) and tap (11) on the front and rear pumps.

Main Control Valve (12) Elbow. (13) Line (swing brake pilot signal).

f. If testing the travel circuit, block the tracks to prevent movement. If testing swing, prevent the swing parking brake from releasing by disconnecting the pilot signal line (13) from elbow (12) and plug. Leave line (13) open to the air.

g. Increase the hydraulic system temperature to the normal operating temperature.

h. Slowly move the pilot control of the circuit being tested and observe when the pump supplying the flow to the circuit begins to show an increase in pressure or when the implement begins to move.

i. When the pump pressure begins to increase or the implement begins to move, check the pilot signal pressure to the main control valve.

j. If checking boom RAISE pilot supply pressure, continue to move the pilot control lever while watching for the pressure to increase at the rear pump tap (10). The instant there is an increase in pressure at the rear pump, check the pilot signal pressure to the main control valve.

k. If checking stick OUT pilot supply pressure, continue to move the pilot control lever while watching for the pressure to increase at the front pump, check the pilot signal pressure to the main control valve.



l. Continue to move the pilot control lever until the implement has reached maximum travel position (tracks blocked to prevent movement or swing brake release signal disconnected).

m. Return the pilot control lever to its NEUTRAL position.

n. Slowly move the pilot control lever of the circuit being tested in the direction of the bottomed implement.

o. The instant the pump reaches main system relief pressure [23 000 kPa (3350 psi) swing, 31 400 kPa (4550 psi) implement, or 34 300 kPa (5000 psi) travel], check the pilot signal pressure of the circuit being tested.

Expected Result:

* At approximately 700 kPa (100 psi) pilot signal pressure the pressure should begin to increase at gauge of the pump supplying flow to circuit being tested or movement of an implement may be seen (initial movement of the boom LOWER, stick IN, and bucket CLOSE functions may not cause an increase in pump pressure because gravity will cause them to move). * If boom RAISE or stick IN or OUT is the function being tested, at approximately 1100 kPa (160 psi) pilot signal pressure the pressure should begin to increase at the second pump. * At approximately 2200 kPa (320 psi) pilot signal pressure the pump(s) should be at system relief pressure indicating the main control valve spool has completely shifted.

Swing Motor Case Drain Test

Introduction

Internal leakage of the swing motor (case drain leakage) can be an indication of the condition of the motor. Excessive case drain leakage could lead to swing control, speed, and force complaints.

Check swing motor case drain leakage.

Swing Gear (1) Mark (upper structure). (2) Mark (lower structure). (3) Mark (lower structure).



a. Place the machine on level ground and position the upper structure straight ahead so a bolt in the upper structure is aligned with a bolt in the lower as shown.

b. Place mark (1) at the bolt in the upper structure.

c. Place mark (2) on the lower structure so that it is midway between the second and third bolts. Place mark (3) on the lower structure so that it is midway between the third and fourth bolts of the lower structure.

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

Main Control Valve (4) Elbow. (5) Line (swing parking brake signal).

e. Disconnect pilot signal line (5) from swing brake control housing elbow (4) and cap line (5). Leave elbow (4) at the swing brake control housing open.

Swing Motor (6) Line (swing motor case drain).

f. Disconnect swing motor case drain line (6) from the motor and block the line.

g. Connect the vinyl hose to the swing motor case drain port and place the other end in a suitable container.

h. Increase the hydraulic oil temperature to the normal operating temperature.

i. Move the swing pilot control lever to the full LEFT or RIGHT swing position.

j. Measure the case drain leakage for 15 seconds while holding the swing pilot control lever in the full swing position (at swing system relief pressure).

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



l. Reconnect swing parking brake pilot signal line (5) to the swing brake control housing elbow (4).

m. Move the upper structure so that mark (1) is aligned with mark (2) on the lower structure.

n. Repeat Steps d, e, i, and j.

o. Repeat Steps k, and l.

p. Move the upper structure so that mark (1) is aligned with mark (3) on the lower structure.

q. Repeat Steps d, e, i, and j.

r. Calculate the average the three case drain measurements. (Add the three case drain measurements and then divide them by 3. Multiply the result by 4 to determine the amount of case drain flow per minute.)

Expected Result:

The average of the case drain measurements should be 15 liter/min (4.0 U.S.gpm) for a new motor, 17 liter/min (4.5 U.S.gpm) for a rebuilt motor and a service limit of 20 liter/min (5.3 U.S.gpm).

Travel Motor Case Drain Test

Introduction

Internal leakage of the travel motor (case drain leakage) can be an indication of the condition of the motor. Excessive case drain leakage could lead to travel stall at high drive pressures.

Measure travel motor case drain leakage.

a. Place the machine on a level surface and stop the engine.

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



Travel Motor (1) Line (travel motor case drain).

c. Disconnect drain line (1) from the connector at the travel motor being tested and install a plug (9/16-18UN) in the open end of drain line (1).

d. Connect one end of the vinyl hose to the connector at the motor and place the other end into a suitable container.

e. Start the engine.

f. Set the engine speed dial at position "10" and the power mode selector switch in MODE III position.

g. Increase the hydraulic oil temperature to the normal operating temperature.

2. Install the 5P-6214 track block assembly to prevent the track being tested from moving.

i. Move the travel pilot control pedal (lever) of the travel to be tested to the full FORWARD position.

j. Hold the travel pedal (lever) at the full FORWARD position for 15 seconds and measure the amount of case drain oil.

k. Remove the 5P-6214 Track Block Assembly and move the machine FORWARD 1/8 turn (45°) of the track sprocket.

l. Repeat steps h through j.

m. Remove the 5P-6214 Track Block Assembly and move the machine FORWARD another 1/8 turn (45°) of the track sprocket.

n. Repeat steps h through j.

o. Calculate the average of the three case drain measurements. (Add the three measurements and divide by 3. Multiply the results by 4 to determine amount of case drain per minute).

Expected Result:

The average of the case drain measurements should be 20 liter/min. (5.3 U.S.gpm) for a new motor, 23 liter/min. (6.1 U.S.gpm) for a rebuilt motor and a service limit of 26 liter/min. (6.9 U.S.gpm).



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. Shut off 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 air vent plug on the hydraulic tank and release the pressure.

7. Tighten the air vent plug 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 PumpsWhen the main pumps have been serviced or the hydraulic oil 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, disconnect hose (1) from the top of the main pump. Leave the hose disconnected for several minutes until the main pumps are filled with oil. Connect hose (1) to the



top of the main pumps and start the engine in low idle and 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 hose (1) until oil flows out of the hose opening. This is an indication that the air has been released from the pump.

4. Tighten the 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.

Hydraulic Component Layout (1) Right travel motor. (2) Pilot oil manifold. (3) Main control valves. (4) Swing motor. (5) Boom. (6) Cab. (7) Left travel motor.



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 (front pump). (3) Tap (rear pump).

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

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

3. Connect 60 000 kPa (8700 psi) pressure gauge to either the main pump tap (2) or tap (3).

4. Connect a 4000 kPa (580 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". Make sure that engine speed under a no load condition is 2180 ± 80 rpm and the AEC switch is in the OFF position. (Read rpm after an elapse of 3 seconds once the speed dial has been placed in position "10".)

Pilot Relief Valve Adjustment



Preparation


Pilot Oil Manifold Compartment (25) Tap. (pilot pump delivery pressure). (26) Screw. (27) Locknut. (28) Pilot relief valve.


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

3. Connect a 4000 kPa (580 psi) pressure gauge to tap (25).

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

5. Place the power mode selector switch in MODE III position.

6. Place the engine speed dial at position "10". 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 section, "Operational Test Preparations" 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 (27) of pilot relief valve (28).

2. Turn screw (26) until the pressure gauge at tap (25) reads 3450 ± 200 kPa (500 ± 30 psi)



Reference: Turning screw (26) clockwise increases the pressure and turning screw (26) counterclockwise decreases the pressure.

Tighten locknut (27) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).

NOTE: Always make final pressure adjustments on pressure rise.

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. Place the machine on level ground and stop the engine. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic System".

2. Slowly move the bucket control lever to the BUCKET OPEN position (full cylinder rod retraction).

3. Check to be sure the main relief valve pressure setting is 31 400 ± 490 kPa (4550 ± 72 psi). See the section "Main Relief Valve Adjustment".


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

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

Swing Crossover Relief Valve Pressure Check

Swing Motor Compartment (21) Crossover relief valve (right swing). (22) Crossover relief valve (left swing).



Main Control Valve Compartment (23) Elbow. (24) Pilot line (swing parking brake).


Preparation


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

3. Attach a 60 000 kPa (8700 psi) pressure gauge to tap (3).

4. Engage the swing parking brake as follows:

a. Disconnect pilot line (24) from elbow (23).

b. Install a cap (716-20HD) on elbow (23). Leave the end of pilot line (24) open to the air.

5. Start and run the engine at high idle (2180 ± 80 rpm). Place the power mode selector switch at MODE III position.

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

Check Procedure

1. Slowly move the swing pilot control lever to the FULL RIGHT SWING position and check the pressure of relief valve (21) at tap (3).

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



2. If the pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new relief valve.

3. To check the relief valve for left swing, slowly move the swing pilot control lever to the FULL LEFT position and check the pressure of relief valve (22) at tap (3).

4. If the pressure reading is not 23 000 ± 980 kPa (3350 ± 140 psi), replace with a new relief valve.

5. After pressure check, disengage the swing parking brake as follows:

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

b. Remove the cap (716-20UN) from elbow (23).

c. Connect pilot line (24) to elbow (23).

Adjustment Of Line Relief Valve Pressure

Preparation


1. Start the service program "Calibration Mode" and keep the power shift pressure constant at 2250 kPa (325 psi). Read the pressure gauge attached at tap (1) to monitor the power shift pressure.

NOTE: For further information of "Calibration Mode" see the section in this module "Calibration Mode".

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

2. 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.



Main Control Valve Compartment (Viewed From Machine Rear) (9) Screw. (10) Locknut. (11) Line relief valve (boom cylinder head end). (12) Line relief valve (bucket cylinder head end). (13) Line relief valve (stick cylinder rod end). (14) Line relief valve (stick cylinder head end).

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

NOTE: All of the line relief valves are identical in construction and operation. To adjust the line relief pressure, loosen locknut (10) and turn screw (9). Turning screw (9) clockwise increases the pressure and turning screw (9) counterclockwise decreases the pressure.

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 (10) and turn screw (9) until line relief valve pressure at tap (3) reads 33 300 ± 1470 kPa (4850 ± 215 psi). Turning screw (9) clockwise increases the pressure and turning screw (9) 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 33 300 ± 1470 kPa (4850 ± 215 psi) using the same procedure as that described for the stick cylinder.



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 boom 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 33 300 ± 1470 kPa (4850 ± 215 psi) using the same procedure as that described for the stick cylinder.

NOTE: Always make final pressure adjustments on the 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 section in the module, "Engine And Pump Electronic Control System, Calibration Mode Stop Procedure".

NOTE: After adjustment of the line relief valves, return the main relief pressure to its normal setting.

Travel Crossover Relief Valve Adjustment

Sprocket (Left Track) (15) Sprocket. (16) Stopper.

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




Preparation

1. Start Service Program "Calibration Mode" and maintain power shift pressure at 2250 kPa (325 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 the OFF position.

2. Block forward left travel, by putting stopper (16) in position on the gear of sprocket (15), as shown above.


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 36 300 ± 1470 kPa (5250 ± 215 psi). To adjust crossover relief valve (20), loosen locknut (18) and turn screw (17) until the pressure gauge at tap (3) reads 36 300 ± 1470 kPa (5250 ± 215 psi).

3. Tighten locknut (18) to a torque of 44 ± 5 N·m (33 ± 4 lb ft).


4. Position stopper (16) 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 (19) at tap (3). Adjust the pressure of crossover relief valve (19) 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 section in the module, "Engine And Pump, Electronic Control System, Calibration Mode Stop Procedure".

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.


Top Of Main Control Valves (4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.


Preparation



3. Attach a 60 000 kPa (8700 psi) pressure gauge to tap (2).

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) (15) Sprocket. (16) Stopper.

1. Block forward left travel by putting stopper (16) in position on the gear of sprocket (15).

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 (2) reads 34 300 ± 490 kPa (5000 ± 71 psi). Tighten locknut (7) to a torque of 29 ± 2 N·m (22 ± 1 lb ft).

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


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 (3) reads 31 400 ± 490 kPa (4550 ± 72 psi). Tighten locknut (5) to a torque of 29 ± 2 N·m (22 ± 1 lb ft).

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




Adjustment Of Automatic Travel Speed Travel Change Valve

Preparation

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


Pump Compartment (1) Tap (rear pump).

3. Install 60 000 kPa (8700 psi) pressure gauge at tap (1) of the rear pump.

Pilot Oil Manifold Compartment (2) Tap (pilot pump delivery pressure).

4. Install 4000 kPa (580 psi) pressure gauge at tap (2).



Travel Motor (Left Track) (3) Signal line.

5. Disconnect signal line (3) from the travel motor. Install a tee on the port that the signal line was removed from and connect signal line (3) to tee. Attach a 4000 kPa (580 psi) pressure gauge to the tee.

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 at 2180 ± 80 rpm with the AEC switch in the OFF position.

Sprocket (Left Track) (4) Sprocket. (5) Stopper.

8. Block the forward left travel by putting stopper (5) in position on the gear of sprocket (4), 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).


Pilot Oil Manifold Compartment (6) Automatic travel speed change valve. (A) Viewed from A side.



Automatic Travel Speed Change Valve (Viewed From A Side). (6) Automatic travel speed change valve. (7) Screw. (8) Locknut.

1. While reading the pressure gauges connected to the tee in signal line (3) and to tap (1), slowly move the left travel control lever/pedal to the FORWARD position. When the pressure at tap (1) reads 31 700 ± 980 kPa (4600 ± 140 psi), the pressure gauge connected to signal line (3) 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 (turtle) speed.

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

3. If the pressure gauge connected to signal line (3) does not read 0 kPa (0 psi) at the time the system pressure at tap (1) reads 31 700 ± 980 kPa (4600 ± 140 psi), then adjust automatic travel speed change valve (6) as follows:


a. Loosen locknut (8) and turn screw (7) until the pressure gauge connected to line (3) reads 0 kPa (0 psi) when the pressure gauge at tap (1) reads 31 700 ± 980 kPa (4600 ± 140 psi).

b. Tighten locknut (8) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).

NOTE: Turning screw (7) clockwise increases the pressure. Turning screw (7) 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 13 700 ± 490 kPa (2000 ± 71 psi). Now the pressure gauge connected to signal line (3) 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 the action alarm indicators indicate a normal condition, 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. The "Pump Flow Tests" should then be performed.



NOTE: If the operational tests indicate an 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 (Constant Horsepower Control Test) (Main Pump) (1) Portable hydraulic tester (flow meter). (2) O-ring seal. (3) Sleeve. (4) O-ring seal. (5) Nipple. (6) Coupler. (7) Coupling. (8) Sleeve. (9) Hose. (10) Elbow. (11) O-ring seal. (12) Plug. (13) Tee. (16) Outlet line (front pump). (17) Outlet line (rear pump). (14) Front pump. (15) Rear pump. (18) Makeup line. (19) Swing motor.



Preparation (Front Pump)

Circuit Diagram For Flow Test (Under Constant Horsepower Control) (Front Pump) (1) Portable hydraulic tester (flow meter). (12) Plug (front pump delivery line). (16) Outlet line (front pump). (17) Outlet line (rear pump). (14) Front pump. (15) Rear pump. (18) Makeup line. (19) Swing motor. (21) Main control valves. (22) Pressure gauge. (23) Tap (front pump). (24) Tap (power shift pressure). (25) Tap (rear pump). (26) Engine. (20) Multitach.

Pump Compartment (9) Hose. (12) Plug. (14) Front pump. (15) Rear pump. (16) Outlet line (front pump). (23) Tap (front pump). (24) Tap (power shift pressure). (25) Tap (rear pump).



Swing Motor Compartment (Top View) (13) Tee. (19) Swing motor.

Flow Meter (1) Portable hydraulic tester (flow meter). (9) Hose. (20) Multitach. (27) 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 flow meter valve is

fully open (turned counterclockwise).

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


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

a. Disconnect outlet line (16) from front pump (14).

b. Install plug (12) and O-ring seal (11) to the end of outlet line (16).

c. Disconnect makeup line (18) from the connector of swing motor (19).

d. Install tee (13) and two O-ring seals (11) to the connector. Connect makeup line (18) and O-ring seal (11) to tee (13).

e. Connect portable hydraulic tester (flow meter) (1) between front pump (14) and tee (13).



f. Install pressure gauge (22) at power shift pressure tap (24). Install pressure gauge (22) at front pump tap (23). Tap (24) is used to measure the power shift pressure. Tap (23) is used to measure the front pump delivery pressure.

NOTE: A 60 000 kPa (8700 psi) pressure gauge can be used in place of pressure gauge (22).

g. Install multitach group (20) on engine (26). 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 2180 ± 80 rpmwith 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 (Rear Pump)

Pump Compartment (12) Plug (rear pump outlet line). (15) Outlet line (rear pump). (17) Rear pump. (26) Tap (rear pump).

Perform the same preparation as that described for the front pump flow test under constant horsepower control except Step 3. Use the following procedure in replacement for Step 3, for the rear pump (15):

a. Disconnect outlet line (17) from rear pump (15).



d. Install tee (13) and two O-ring seals (11) to the connector. Connect makeup line (18) and O-ring seal (11) to tee (13).

e. Connect flow meter (1) between rear pump (15) and tee (13).

f. Install pressure gauge (22) at power shift pressure tap (24). Install pressure gauge (22) at rear pump tap (25). Tap (24) is used to measure the power shift pressure. Tap (25) is used to measure the rear pump delivery pressure.

NOTE: A 60 000 kPa (8700 psi) pressure gauge can be used in place of pressure gauge (22).

g. Install multitach group (20) on engine (26).



Test Procedure

NOTE: Perform the front and rear pump flow tests one at a time.



To prevent personal injury and/or equipment damage from failed lines or components while the flow meter is returned to the open flow

position after a flow test, slowly open the flow meter valve and monitor pump flow at the same time to make sure flow increases. If pump flow does not increase as the flow meter is opened, shut the engine off and

determine what is causing the pump not to upstroke.

1. With the engine running, start the service program "Calibration Mode" and maintain the power shift pressure at a constant pressure of 1850 ± 50 kPa (270 ± 7 psi). The power shift pressure is readat tap (24), using pressure gauge (22).

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 (27) of portable hydraulic tester (1) clockwise and record pump flow at each of the following pressure points. Use pressure gauge (22) at tap (23) or (25) for this pressure reading.



P-Q Characteristic Curve

NOTE: Flow specifications given above are based on an engine speed of 2100 rpm. To get more accurate test results, each of measurements should be corrected by calculating as follows:

Flow corrected = (Flow measured /mu/ 2100) ÷ rpm measured

1. Any flow readings must be done only in upstroke.

2. The pump flow changes approximately 5.5 liter/min (1.5 U.S. gpm) for each 98 kPa (15.5 psi) of power shift pressure.



Negative Flow Control Test



Ilustration Of Flow Meter Tool Layout (Negative Flow Control Test) (Main Pumps) (1) Portable hydraulic tester (flow meter). (2) O-ring seal. (3) Adapter block. (4) O-ring seal. (5) Nipple. (6) Coupler. (7) Reusable coupling. (8) Sleeve. (9) Hose. (10) Elbow. (11) O-ring seal. (12) Plug. (13) Tee. (14) Front pump. (15) Rear pump. (16) Outlet line (front pump). (17) Outlet line (rear pump). (18) Makeup line. (19) Swing motor.



Preparation (Front Pump)

Circuit Diagram For Negative Flow Control Test (Front Pump) (1) Portable hydraulic tester (flow meter). (9) Hose. (12) Plug (front pump delivery line). (14) Front pump. (15) Rear pump. (16) Delivery line (front pump). (17) Delivery line (front pump). (19) Swing motor. (20) Main control valves. (21) Negative flow control line. (22) Pressure gauge. (23) Tap (front pump). (24) Pilot oil manifold. (25) Tap (rear pump). (26) Tap. (27) Tee. (28) Test hose. (29) Plug. (30) Pressure gauge. (31) Engine. (32) Multitach. (33) Negative flow control line.

Pump Compartment (9) Hose. (12) Plug. (14) Outlet line (front pump). (21) Negative flow control line (front pump). (23) Tap (front pump).



Illustration Of Tool Layout (Negative Flow Control Test)(Main Pump) (24) Pilot oil manifold. (26) Tap. (27) Tee. (28) Test hose. (29) Plug. (30) Pressure gauge. (36) Coupler. (37) Nipple. (38) O-ring. (39) Coupler. (40) Elbow (to negative flow control port).

Portable Hydraulic Tester (Flow Meter) (1) Portable hydraulic tester (flow meter). (22) Pressure guage. (32) Multitach. (34) Valve (flow meter).



Swing Motor Compartment (9) Hose. (13) Tee. (18) Make up line. (19) Swing motor.

Pilot Oil Manifold Compartment (24) Pilot oil manifold. (26) Tap. (35) Pilot relief valve.

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 illustration and circuit diagram:

a. Disconnect outlet line (16) from front pump (14).



d. Install tee (13) and O-ring seal (11) to the connector. Connect makeup line (18) and O-ring seal (11) to tee (13).

e. Connect portable hydraulic tester (1) between front pump (14) and tee (13).

f. Disconnect negative flow control line (21) from front pump (14) and install plug (29) in the open end of negative flow control line (21).

g. Install tee (27) to elbow (40).

h. Connect hose (28) between tee (27) and tap (26) of pilot oil manifold (24).

i. Install pressure gauge (22) at front pump tap (23). A 60 000 kPa (8700 psi) pressure gauge can be used in place of pressure gauge (22). Tap (23) is used to measure the front pump delivery pressure.



j. Install pressure gauge (30) to tee (27). A 4000 kPa (500 psi) pressure gauge can be used in place of pressure gauge (30).

k. Install multitach group (32) on engine (31).

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 2180 ± 80 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 (Rear Pump)

Pump Compartment (9) Hose. (12) Plug (rear pump outlet line). (15) Outlet line (rear pump). (25) Tap (rear pump). (35) Negative flow control line (rear pump).

Perform the same preparation as that described for the front pump flow test under constant horsepower control except Step 3. Use the following procedure in replacement for Step 3, for the rear pump (15):

a. Disconnect outlet line (17) from rear pump (15).



d. Install tee (13) and O-ring seal (11) to the connector. Connect makeup line (18) and O-ring seal (11) to tee (13).

e. Connect portable hydraulic tester (1) between rear pump (15) and tee (13).

f. Disconnect negative flow control line (33) from rear pump (15) and install plug (29) in the open end of negative flow control line (33).

g. Install tee (27) to elbow (40).

h. Connect hose (28) between tee (27) and tap (26) of pilot oil manifold (24).

i. Install pressure gauge (22) at rear pump tap (25). A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (22). Tap (25) is used to measure the rear pump delivery pressure.



j. Install pressure gauge (30) to tee (27). A 4900 kPa (700 psi) pressure gauge can be used in place of pressure gauge (30).

k. Install multitach group (32) on engine (31). This is used to read engine speed.

Test Procedure

NOTE: Perform the front and rear pump negative flow control tests one at a time.



To prevent personal injury and/or equipment damage from failed lines or components while the flow meter is returned to the open flow position after a flow test, slowly open the flow meter valve and

moneases. 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.nd determine what is causing the pump not to upstroke.

1. Place the power mode selector switch to MODE III position.

2. Place engine speed dial at position "10" and maintain the maximum no load speed at 2180 ± 80 rpm with the AEC switch in the OFF position. (Read the rpm three seconds after engine speed dial has been placed in position "10".)

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

4. Slowly turn valve (34) of portable hydraulic tester (1) clockwise until the pump delivery pressure setting is 6850 kPa (1000 psi).

5. Adjust pilot relief valve (35) of pilot oil manifold (24) until pressure gauge (30) connected to tee (27) reads 2350 kPa (340 psi).

6. Record the negative control flow at each of the following pressure points:



7. Read just pilot relief valve (35) to 2950 kPa (425 psi).

8. Record the pump flow at this negative pressure point.

NOTE: Flow specifications given above are based on an engine speed of 2100 rpm. To get more accurate test results, measured flow should be corrected by calculating as follows:

Flow corrected = (Flow measured x 2100) ÷ rpm measured



P-Q Characteristic Curve [Negative Flow Control at 6850 kPa (1000 psi) Pump Delivery Pressure]

Pump Flow AdjustmentIf the flow measurements are out of specification, adjust the flow using the following procedures:

NOTE: Any flow variation per one turn of a setscrew should be used as a guide only. Always use a portable hydraulic tester to adjust the pump flow.



Flow Adjustment Under Constant Horsepower Control

Main Pump (1) Setscrew. (2) Locknut. (3) Setscrew. (4) Locknut. (5) Locknut. (6) Setscrew. (7) Setscrew. (8) Setscrew. (9) Setscrew.

Flow adjustment procedure for the front and rear pumps under constant horsepower control is the same. Setscrew (3) and (8) are for the lower pressure range where the first stage spring in each pump regulator activates. Setscrews (1) and (9) are for the higher pressure range where the second stage spring in each regulator activates.

Front Pump Adjustment

1. Loosen locknut (4).

2. Turn setscrew (3) until adjusted to the correct specification. Turning setscrew (3) 1/4 turn clockwise increases the flow rate approximately 10.7 liter/min (2.8 U.S.gpm) at a system pressure of 13 700 kPa (2000 psi) and 17 700 kPa (2550 psi) where the first stage spring activates.



5. Turn setscrew (1) until adjusted to the correct specification. Turning setscrew (1) 1/4 turn clockwise increases the flow rate approximately 4.8 liter/min (1.3 U.S.gpm) at a system pressure of 23 500 kPa (3400 psi) and 29 400 kPa (4250 psi) where the second stage spring activates.


Rear Pump Adjustment

To adjust the rear pump flow under constant horsepower control do the same as that described above using setscrews (8) and (9).



Maximum Flow Adjustment

Maximum flow adjustment procedure for front and rear pumps is the same. Use setscrew (6) for the front pump and setscrew (7) for the rear pump.


2. Turn setscrew (6) until adjusted to the correct specification. Turning the setscrew 1/4 turn clockwise decreases flow rate approximately 3.0 liter/min (.8 U.S.gpm).


Negative Flow Control Adjustment

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

Rear Pump (Viewed From Drive Shaft Side) (45) Setscrew.

Negative flow control adjustment procedure for front and rear pumps is the same. Use setscrew (45) for the front pump and setscrew (44) for the rear pump.




2. Turn setscrew (44) until adjusted to the correct specification. Turning the setscrew 1/4 turn clockwise increases the flow rate approximately 7.8 liter/min (2.1-U.S.gpm) at a negative control pressure of 2450 kPa (355 psi).


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318b pump flow test

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