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Producto: EXCAVATOR
Modelo: 320 L EXCAVATOR 1KL
Configuracin: 320, 320L TRACK-TYPE EXCAVATORS 1KL00001-UP
(MACHINE) POWERED BY 3066 ENGINE
Pruebas y Ajustes
320 AND 320L EXCAVATORS HYDRAULIC AND ELECTRONIC SYSTEMS
Nmero de medio -SENR5473-02
Introduction
This manual contains information on the troubleshooting procedures of the electronic control and hydraulic
systems in the 320 and 320 L Excavator. This manual is divided into the following three main sections:
1. Electronic System Testing And Adjusting
2. Checking Procedures
3. Hydraulic System 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,
Electronic System", Form SENR5463 and/or "Systems Operation, Hydraulic System", Form SENR5464.
For troubleshooting the engine components, refer to: "Systems Operation, Testing And Adjusting, Basic
Engine Components 3306 Engine", Form SENR5546.
Checking Procedures
In each checking procedure, it is assumed that the engine operation is normal unless otherwise specified.
Operational Tests
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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.
Service Program
Electronic Monitor Panel
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(1) Engine coolant temperature gauge. (2) Fuel gauge. (3) Action lamp. (4) Character display. (5) Monitor panel. (6) Hydraulic oil
temperature gauge. (7) Work mode selector switch. (8) Air heater indicator. (9) Charge alarm indicator. (10) Engine coolant
temperature alarm indicator. (11) Hydraulic oil temperature alarm indicator. (12) Engine oil pressure alarm indicator. (13)
Controller alarm indicator. (14) Monitor alarm indicator. (15) Work mode boom priority indicator. (16) Work mode swing priority
indicator. (17) Power mode selector switch. (18) Power mode III indicator. (19) Power mode II indicator. (20) Power mode I
indicator. (21) Work mode fine control indicator. (22) Light switch. (23) Light 1 indicator. (24) Light 2 indicator. (25) Wiper 2
indicator. (26) Travel speed HIGH (rabbit) indicator. (27) Travel speed LOW (tortoise) indicator. (28) Travel speed control
switch. (29) AEC indicator. (30) Switch panel. (31) AEC switch. (32) Wiper 1 indicator. (33) Washer indicator. (34) Washer
switch. (35) Wiper switch. (36) Alarm cancel switch. (37) Service switch. (38) Alarm cancel indicator.
Introduction
The electronic Monitor Panel activates and displays the output received from the Electronic Controller. The
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Electronic Controller Service Program is divided into two program modes. Each program mode has a
particular function as follows:
1. Data Mode;
This program mode contains eight function modes and provides the necessary information for the
mechanic to determine the machine condition.
2. Calibration Mode;
This program mode contains ten function modes and provides information used to adjust and confirm
system/component functions after replacement of electronic control system components. This
program level is also used to help the mechanic troubleshoot machine problems.
To activate the service program mode functions, use the control switches provided on the electronic monitor
panel.
NOTE: Unexpected character display readings due to random operation of switches should be disregarded.
To select a desired function mode, first start a proper service program mode (see the section "Data Mode
Start-up" and/or "Calibration Mode Start-up"). Next, operate the control switch(es) as specified, until the
desired information is indicated on the character display.
When the selected service program function is no longer needed, use the proper procedure (see the section
"Data Mode Stop Procedure" and/or "Calibration Mode Stop Procedure") to cancel.
Data Mode
NOTE: Activation of service program "Data Mode" does not affect any machine controls and operations
except for the following:
The LED indicators for power mode switch, travel speed control switch, light switch, and wiper switch come
ON only in flashing mode during activation of service program "Data Mode".
The Data Mode contains the following function modes which provide eight categories of information.
1. Power shift pressure.
2. Engine speed.
3. Engine coolant temperature.
4. Hydraulic oil temperature.
5. A/D (Analog/Digital) conversion.
6. Real time error.
7. Digital input.
8. Output control display.
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NOTE: To access and view the eight available functions in the "Data Mode", the engine can either be
running or shut down. If the engine is running the eight Data Mode functions can be viewed as operating
values. If the engine is not running the starter switch must be in the "ON" position.
1. Depress and hold alarm cancel switch (36) until alarm cancel indicator (38) starts flashing.
2. While alarm cancel switch (36) is depressed, push power mode selector switch (17) until power mode III
indicator (18) begins to flash. Release alarm cancel switch (36) and power mode selector switch (17).
3. The service program "Data Mode" is now activated and character display (4) will display the first function
mode (power shift pressure) value.
NOTE: If switch (17) is held too long, the character display will sequence through the eight available
function modes in the "Data Mode" program.
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1. Repeatedly push first alarm cancel switch (36) and then power mode switch (17) until the desired
function mode is displayed on character display (4).
2. Each time both switches are pushed, the function mode changes in an increasing number sequence of the
eight function modes in a repetitious manner.
3. At the same time that the function mode character is displayed the corresponding switch indicator comes
on. To determine the function mode selected, look for the switch indicator which is flashing.
NOTE: If alarm cancel switch (36) is depressed for more than 2 seconds the Data Mode stops and character
display (4) displays the engine speed dial position.
NOTE: Accessing the "Data Mode Functions" must be performed in the sequence shown in the following
chart.
Each of the eight Data Mode functions has a designated indicator light. The following chart shows the eight
Data Mode functions and their designated indicator lights:
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When this function mode is selected, power mode III indicator (18) flashes. The character display (4)
displays "P" in the first position and actual power shift pressure in the second and third positions. The unit of
power shift pressure is in kgf/cm2. 1 kgf/cm2 is approximately the same as 100 kPa (14 psi).
Engine Speed
When this function mode is selected, power mode II indicator (19) flashes. Character display (4) will display
the engine speed in rpm, regardless of the machine load. Multiply the rpm values in character display (4) by
10 to determine actual rpm.
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When this function mode is selected, power mode I indicator (20) flashes. Character display (4) displays the
engine coolant temperature within a range of 14C to 127C (57F to 260F). The engine coolant
temperature units are displayed in 1C (1.8F) increments. If the character display reading is below 0C, the
first position on the character display reads "-".
NOTE: Character display (4) displays the engine coolant temperature in degrees Celsius.
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When this function mode is selected, light 1 indicator (23) flashes. Character display (4) displays the
hydraulic oil temperature within a range of 14C to 127C (57.2F to 260.6F). The hydraulic oil
temperature units are displayed in 1C (1.8F) increments.
NOTE: Character display (4) displays the hydraulic oil temperature in degrees Celsius.
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When the analog/digital conversion function mode is selected, light 2 indicator (24) flashes. Character
display (4) displays the analog information for eight machine functions. A conversion chart is needed to
understand the digital information indicated. Description of the eight machine functions omitted since this
information is not needed for service or diagnosis.
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When this mode is selected, travel speed HIGH (rabbit) indicator (26) flashes. Character display (4) displays
the codes for problems that have occurred. They are displayed in an increasing number sequence according
to "Problem List" shown below, in a repetitious manner. A character display code remains displayed for 2
seconds with an interval of 1 second between codes.
NOTE: A display code of [E00] indicates that there are no system errors.
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NOTE: Go to the appropriate "Electronic Sequence Chart" to troubleshoot the problem of [E33] in
accordance with the following:
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Digital Input
When this mode is selected, travel speed LOW (tortoise) indicator (27) flashes. This mode displays 21 types
of information on character display (4).
1. Depress and hold alarm cancel switch (36) and then depress power mode switch (17) until travel speed
LOW (tortoise) indicator (27) flashes. Release alarm cancel switch (36) and power mode switch (17).
2. Character display (4) will display [0 9]. The "0" indicates that this is the first of 21 "ports" or additional
types of information. The " 9" indicates the wiring harness code for the 320 and 320 L Excavators with 3066
engine.
3. To sequence through the 21 "ports", first depress and hold alarm cancel switch (36) and then work mode
switch (7) until the character display reads the desired "port".
NOTE: This mode is capable of providing a total of 21 types of information. Eight of the 21 "ports"
(additional types of information) are spares.
The following chart gives a listing of the 21 "ports" and their components:
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NOTE: Ports "0" and "1" give no indication of "[ O n] or [ o F] on the character display.
Typical Examples:
[0 9]: Indicates the machine model of "320" or "320 L" excavator with 3066 engine. If a different code
appears in the second and third positions, check the circuit for good grounding.
[1 1]: Engine speed dial is in position "1".
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When this function mode is selected, wiper 1 indicator (32) flashes. Character display (4) displays the code
that represents current pump output. The initial code displayed will be [L00] for a normal pump output
control. The character display code remains ON for 2 seconds with an interval of 0.5 seconds between
codes.
Typical Examples:
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2. Keep alarm cancel switch (36) depressed at least 2 seconds until character display (4) displays the engine
speed dial position.
Calibration Mode
NOTE: The procedures for each function in "Calibration Mode" are independent of each other. The engine
does not need to be running for all the functions listed in the following chart. The following chart lists the
functions in "Calibration Mode" and whether the engine must be running for each of the functions:
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NOTICE
Before to starting the Calibration Mode, the engine speed dial switch
should be set at dial position "1" and the engine start switch must be in
the OFF position.
1. Depress service switch (37) and start the engine. As shown in the chart above, the engine does not need to
be started to obtain information for certain functions in the "Calibration Mode".
2. Continue to depress service switch (37) until action lamp (3) comes ON and character display (4) displays
[20H]. All the alarm indicators except character display (4) will turn OFF.
3. The "Calibration Mode" is now accessed and character display (4) displays the first of the 10 functions
(machine and engine model numbers) as shown in the chart above. Action lamp (3) remains ON during all
calibration function modes.
NOTE: Activation of the "Calibration Mode" overrides the function of engine coolant temperature gauge
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(1), fuel gauge (2), action lamp (3), hydraulic oil temperature gauge (6), air heater indicator (8), charge
alarm indicator (9), engine coolant temperature alarm indicator (10), hydraulic oil temperature alarm
indicator (11), engine oil pressure alarm indicator (12), controller alarm indicator (13), and monitor alarm
indicator (14).
Power mode selector switch (17), light switch (22), AEC switch (31), wiper switch (35), and travel speed
control switch (28) are pushed each time to obtain one of ten function modes.
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Error log
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4. Each time AEC switch (31) is pushed, a different port code appears in character display (4) in an
ascending order. Press washer switch (34) to view the ports in descending order.
5. Press alarm cancel switch (36) to turn the component for each port, either ON or OFF. Character display
(4) displays as shown in the chart above as each port is turned ON or OFF. If an over current occurs at a
component, the character display (4) displays [OEr].
6. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode
Stop Procedure".
NOTE: Activation of the "Calibration Mode" overrides the AEC function and keeps the power shift
pressure constant at a pressure level equivalent to a no-load condition. The engine speed dial switch works
normally.
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1. Stop the engine and disconnect connector (39) from the proportional reducing valve.
2. Connect the test harness to connector (39).
3. Install a 4900 kPa (700 psi) pressure gauge at power shift pressure tap (40).
4. The pump backup switch must be in the "AUT" position.
5. Start "Calibration Mode". See the section, "Calibration Mode Start-up".
NOTE: The engine must be running to obtain accurate information for this test.
6. Warm the hydraulic oil to normal operating temperature.
7. Run the engine at maximum no-load rpm.
8. All controls must be in the NEUTRAL position.
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rpm. Each time AEC switch (31) is depressed, AEC indicator (29) comes ON. Each time washer switch (34)
is depressed, washer indicator (33) comes ON.
5. Character display (4) will increment by 1 (10 rpm).
6. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode
Stop Procedure".
NOTE: Activation of the "Calibration Mode" overrides the AEC function and keeps the power shift
pressure constant at a pressure level equivalent to a no-load condition. Immediately after this mode has been
canceled, engine speed recovers to the original speed dial setting.
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2. Depress wiper switch (35) until wiper 2 indicator (25) comes ON.
3. Character display (4) will display "P" in the first position and the selected power shift pressure in the
second and third positions. As a example the value shown in character display (4) of [P25] is in kgf/cm2. To
convert kgf/cm2 to kPa, multiply the value shown in character display (4) by 100. The resultant power shift
pressure is 2450 kPa (355 psi).
4. Depress AEC switch (31) to increase the power shift pressure command signal by 1 kgf/cm2 within a
range of 3 to 30 kgf/cm2 [290 to 2950 kPa (42 to 430 psi)].
5. Depress washer switch (34) to decrease the power shift pressure command signal by 1 kgf/cm2 within a
range of 3 to 30 kgf/cm2 [290 to 2950 kPa (42 to 430 psi)].
NOTE: Depressing alarm cancel switch (36) causes character display (4) to display alternately between the
power shift pressure and the engine rpm.
NOTE: Refer to "Engine Speed Change" to determine the value of engine speed displayed on character
display (4).
6. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode
Stop Procedure".
NOTE: Activation of the "Calibration Mode" overrides the AEC function. The engine speed dial switch
works normally.
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NOTE: Activation of the "Calibration Mode" overrides the AEC function and keeps the power shift
pressure constant at a pressure level equivalent to a no-load condition. The engine speed dial switch works
normally.
NOTICE
The hydraulic oil temperature must be at the normal operating
temperature before this calibration procedure is performed.
NOTE: This procedure must be performed any time the governor actuator or controller has been replaced or
reinstalled.
NOTE: Activation of this mode overrides the AEC system function, and keeps the power shift pressure
constant at the no load pressure level. The engine speed dial can be placed at any position since it cannot
activate until the governor actuator calibration has been completed. The governor backup switch must be in
AUT (not backup) position.
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NOTE: After initial setting has been completed, check to be sure that the governor lever is correctly
positioned (in contact with the high idle stopper) by rotating the pulley by hand.
* [AC1]
* [AC2]
* [AC3]
* [AC4]
* [AC5]
* [AC6]
* [AC7]
* [AC8]
* [AC0]
When [AC0] appears in character display (4), the calibration procedure is complete.
NOTE: If the data is not correct or within specified limits, character display (4) will indicate an error code
as shown in the following chart:
NOTE: If character display (4) displays [AC2] and [- *] (*: error code shown in the following chart)
alternately during Automatic G/A Calibration procedure, it is an indication of the following possible
problems. Have necessary repairs made. If character display (4) displays [AC0] after taking corrective
action, it indicates that the automatic governor actuator calibration has been completed correctly.
NOTE: If the error code [- 1], [- 2], [-3], [-15], or [-16] is indicated on character display (4), readjust the
accelerator/decelerator cables. See the section "Adjustment After Replacement Of Major Components".
NOTE: If the error code [-4] through [-12] or [-14] is indicated on character display (4), check the
corresponding checking procedure in the section "Checking Procedures (Electronic Control System)".
NOTE: When character display (4) displays [-13], return all controls to the NEUTRAL position. If the
problem code still exists, check the pressure switches and circuits.
NOTE: Even if any of error code [-51], [-52], or [-53] appears after character display (4) has displayed
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[AC0], the machine does not need to be stopped, but can continue to be operated. Since the three codes
indicates that the accelerator cable needs further adjustment, readjustment can be performed later using the
following procedure.
a. If [-51] is displayed for two seconds, readjust the accelerator cable. See the section, "Adjustment After
Replacement Of Major Components".
b. If character display (4) alternates between [-52] and [ 10], every two seconds for example, decrease the
tension in the cable by loosening the adjusting nut of the accelerator cable by one turn. (If [ 15] is indicated,
then loosen the nut one and a half turns.)
c. If character display (4) alternates between [-53] and [ 10], every two seconds for example, increase the
tension in the cable by tightening the adjusting nut of the accelerator cable by one turn.
7. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode
Stop Procedure".
1. Stop the engine and install a 4900 kPa (700 psi) pressure gauge to power shift pressure tap (40).
2. Make sure that the pump control backup switch is in the "AUT" position.
3. Start the "Calibration Mode". Refer to the section "Calibration Mode Start-up".
NOTE: The engine must be running and have a hydraulic oil temperature of approximately 50C (122F) to
perform this calibration procedure.
4. Run the engine with engine speed dial switch at position "10".
NOTE: Activation of this calibration mode overrides the AEC function. If the engine speed dial switch is
not at position "10" character display (4) will show an "E" in the first column. The engine speed must be
corrected within specifications to continue the calibration procedure.
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5. Depress travel speed control switch (28) until travel speed LOW (tortoise) indicator (27) comes ON.
6. Character display (4) now displays [1 0]. The "1" indicates that the first calibration point has been
accessed and the "0" indicates that the middle step of the 19 individual calibration steps has been accessed.
Each step will change the power shift pressure by approximately 50 kPa (7.5 psi).
7. To change the power shift pressure:
a. To increase the power shift pressure, depress AEC switch (31) once. This will change character
display (4) to [1 1]. Each time AEC switch (31) is depressed, character display (4) increases by one
until character display (4) displays [1 9]. Also, the pressure reading at power shift pressure tap (40)
increases by approximately 50 kPa (7.5 psi) for each increase. The following is an example of
character display (4) readings in increasing order:
* [1-9]
* [1-8]
* [1-7]
* [1-6]
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* [1-5]
* [1-4]
* [1-3]
* [1-2]
* [1-1]
* [1 0] = Middle Step
* [1 1]
* [1 2]
* [1 3]
* [1 4]
* [1 5]
* [1 6]
* [1 7]
* [1 8]
* [1 9]
b. To decrease the power shift pressure, depress washer switch (34) once to lower the value displayed
in character display (4). Each time washer switch (34) is depressed, character display (4) decreases by
one in descending order until character display (4) displays [1-9]. Also, the pressure reading at power
shift pressure tap (40) decreases by 50 kPa (7 psi) for each decrease. The following is an example of
character display (4) readings in decreasing order:
* [1 9]
* [1 8]
* [1 7]
* [1 6]
* [1 5]
* [1 4]
* [1 3]
* [1 2]
* [1 1]
* [1 0] = Middle Step
* [1-1]
* [1-2]
* [1-3]
* [1-4]
* [1-5]
* [1-6]
* [1-7]
* [1-8]
* [1-9]
8. To set "Calibration Point No. 1", perform the following steps:
a. Depress washer switch (34) until the pressure reading at tap (40) is less than 490 kPa (72 psi).
b. Depress AEC switch (31) until the pressure reading at tap (40) increases to approximately 490 kPa
(72 psi).
NOTE: Pressure adjustments must always be made as the pressure is being increased.
c. Depress alarm cancel switch (36) to store the data in the controller.
d. Once the data is stored in the controller, display (4) changes to [2 0], which indicates that the first
calibration point has been accepted and the second calibration point can be performed. At this time,
the character display flashing light mode will change to a continuous lighting mode.
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1. Place engine in low idle position and turn the engine start switch to the OFF position.
2. Depress service switch (37) for a minimum of two seconds until character display (4) changes from
"Calibration Mode" to engine speed dial position.
Pump Compartment
(1) Accelerator cable. (2) Governor actuator. (3) Decelerator cable.
Engine Compartment
(4) Pulley. (5) Outer cable wire (decelerator). (6) Inner cable wire (accelerator).
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NOTICE
The engine must not be running prior to adjustment of the engine speed
sensor.
1. With the engine stopped, slowly tighten speed sensor (1) into flywheel housing (5) until magnetic core (3)
is in contact with gear (4).
2. Back out speed sensor 3/4 turn and temporarily tighten locknut (2).
3. With the engine speed dial switch set at position "1" (LOW IDLE position) start the engine.
4. Start service program "Data Mode" and select the engine speed display function.
Reference: Make reference to the section in this module, "Data Mode", "Engine Speed".
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Controller
1. Before removal/installation of the controller, be sure to turn the disconnect switch to the OFF position.
2. Perform the automatic governor calibration procedure.
Reference: See the section in this module, "Automatic Governor Actuator Calibration" in "Calibration
Mode".
3. Perform the proportional reducing valve calibration procedure.
Reference: See the section in this module, "Calibration Of Proportional Reducing Valve" in "Calibration
Mode".
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Checking Procedures
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The harness and connector location charts use black circles as location labels in the general and area
views. Alphabetical letters in the connector and vehicle location column indicate the area views where
they are located. the "*" indicates that it is connected to the component in its harness and/or
components column.
NOTE: Harnesses in partial electric schematics given in the "Checking Procedures" are identified by A, B,
and C, which are also indicated in the general and area views.
NOTE: The material in this module is intended to be used with the separate module, "Electrical Schematic"
Form SENR6015.
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NOTE: The character display on the monitor panel indicates error code on character display (3) assigned
for the real time errors and error log, if problem(s) occurs. The charts that follow should be used to
troubleshoot problems indicated by error code on character display (3).
Preparations (1) provide information on the preliminary arrangements that must be made before
troubleshooting.
Problem description (2) indicates problems shown by the character display on the monitor panel.
Error code on character display (3) indicates specific codes for real time errors and error log. Service
Program selection determines the pattern of the character display.
Check items (4) list items that must be checked with a multimeter.
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a. In the check items (4), "0Ohms" means "there is continuity", whereas "infinite Delta " means that
"there is no continuity".
b. Connector check - [other than()]: 0Ohms.
NOTE: [other than()] means all the terminals and pins except the one specified in ().
The following is an explanation of the terms in "Check items (4)":
Example; (1) - (2) of CONN46M
(1) = Pin number.
- = Short circuit indication.
CONN46 = Connector number.
M = The male (M) or female (F) half of the connector.
Probable causes (5) shows probable cause(s) of a problem.
Solution (6) shows the corrective action that should be taken to solve a particular problem. The statement
"Replace" includes "Repair if possible".
When a continuity check is to be performed, "turn the starter switch to the OFF position". This stops the
power supply to prevent damage to the tester or short-circuiting the power supply.
When a voltage check is to be made, "turn the starter switch to the ON position" to allow power supply. The
engine should be in operation unless otherwise specified. Stable inputs and outputs of controller cannot be
obtained without the engine running.
NOTICE
To avoid damage to electrical components when the power supply is
ON, make sure disconnected connectors and wires do not come in
contact with the machine.
Controller Compartment
(1) LED lamp. (2) Controller.
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Controller receives signal of engine speed other than specified "10" from engine speed dial.
Solution:
Check to ensure that CONN27, 24, and 1 are properly connected. If the problem still exists, troubleshoot
according to the following checking procedure chart.
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Solution:
Check to ensure that CONN44, 3, 1, and 18, and the circuits of speed change switch and governor backup
switch are properly connected. If the problem still exists, troubleshoot according to the following checking
procedure chart.
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Problem:
Governor actuator motor circuit is open or governor backup switch is in "MAN" position.
Solution:
Check to ensure that CONN44, 3, 1, and 18 are properly connected. If the problem still exists, troubleshoot
according to the following checking procedure chart.
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Governor actuator remains deactivated an elapse time of 2.5 seconds after engine speed dial has been
activated.
Solution:
Troubleshoot according to the following checking procedure chart.
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Problem:
Chassis light system problem.
Solution:
Check to ensure that CONN4, 3, and 1 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
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Problem:
Boom light return circuit is shorted to battery voltage.
Solution:
Check to ensure that CONN3 and 1 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
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Solution:
Check to ensure that CONN3 and 1 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
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Check to ensure that CONN3, 4, and 1 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
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Solution:
Check to ensure that CONN31, 14, and 1 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
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Check to ensure that CONN9 and 2 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
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Problem:
Fuel level sensor circuit is shorted to body ground.
Solution:
Check to ensure that CONN49, 10, 9, and 2 are properly connected. If the problem still exists, troubleshoot
according to the following sequence chart.
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Problem:
Battery voltage is abnormal (not within 23 to 32V).
Solution:
Check to ensure that CONN24, 11, 9, 5, 2, and 1, and terminals of alternator, breaker and terminal block are
properly connected. If the problem still exists, troubleshoot according to the following sequence chart.
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Check to ensure that CONN1 and 3, and terminals of heater relay, terminal block and air heater are properly
connected. If the problem still exists, troubleshoot according to the following sequence chart.
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Problem:
Governor actuator feedback sensor voltage is too low ([E 9]) or not stable ([E 12]).
Solution:
With the AEC switch in the OFF position, place the engine speed dial at position "10". Check to see if the
voltage between terminal 21 of controller connector B and ground is 6.3 to 6.7 V. If the voltage is within 6.3
to 6.7, it is normal. If not, check or replace the governor actuator, as necessary.
NOTE: To check voltages, see in this module, "Controller Connector Terminal Voltage".
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[Elec #25] There Is More Than 100 rpm Difference Between Engine
Speed Dial Setting And Actual Speed
Problem:
There is more than 100 rpm difference between engine speed dial setting (speed calculated from governor
actuator feedback signal) and actual speed.
Solution:
Troubleshoot according to the following sequence chart.
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Solution:
Troubleshoot according to the following sequence chart.
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Solution:
Troubleshoot according to the following sequence chart.
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Engine stalls.
Solution:
Troubleshoot according to the following sequence chart.
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(Hyd #3-4) Check And Adjustment Of Travel Crossover Relief Valve Pressure
Reference: Refer to the section in this module, "Hydraulic System Testing And Adjusting".
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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.
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To check the swing motor performance, measure the amount of swing motor case drain oil as follows:
1. Disconnect case drain hose (3) from tee (2) on the swing motor.
2. Install a plug in the end of case drain hose (3) and a cap in the open end of tee (2).
3. Disconnect case drain hose (1) from the swivel.
4. Install a cap in the open port of the swivel.
5. Put the open end of case drain hose (1) into a suitable measuring container.
6. With the swing pin in the LOCKED position, operate the swing control for one minute.
7. Measure the amount of swing motor case drain oil.
NOTE: The maximum acceptable case drain oil with a swing relief pressure setting of 24 000 490 kPa
(3500 72 psi) must be:
For a New swing motor ... 20 liter/min (5.3 U.S. gpm)
For a Rebuilt swing motor ... 23 liter/min (6.1 U.S. gpm)
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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, "Release Of Pressure In
The Hydraulic System".
2. Disconnect case drain hose (3) from tee (2) on the swing motor.
3. Install a plug (3/4-16UN) in the end of case drain hose (3) and a cap (3/4-16UN) in the open end of tee
(2).
4. Disconnect case drain hose (1) from the swivel. Put the open end of case drain hose (1) into a suitable
measuring container.
5. Install a cap (3/4-16UN) in the open port of the swivel.
6. Engage the swing parking brake as follows;
a. Disconnect pilot line (5) from elbow (4).
b. Install a cap (9/16-18HD)(6) on elbow (4). Leave the end of pilot line (5) open to the air.
7. Start and run the engine at no-load high idle speed of 1860 50 rpm with the power mode selector switch
at Mode III position.
8. Increase the hydraulic oil temperature to 55 5C (131 9F).
9. Operate the swing control for one minute. Measure the amount of swing motor case drain oil and record
the measurement.
NOTE: Check to be sure that the swing parking brake is correctly being engaged while the swing control is
activated.
10. Release the swing parking brake as follows:
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a. Stop the engine and release the pressure in the hydraulic system. See the section, "Release Of
Pressure In The Hydraulic System".
b. Remove cap (9/16-18HD)(8S4950)(6) from elbow (4).
c. Connect pilot hose (5) to elbow (4).
11. Operate the swing control to place the swing motor barrel in a new position.
12. Repeat Steps 1 through 9. Take three measurements.
NOTE: The maximum acceptable case drain oil with a swing relief pressure setting of 24 000 490 kPa
(3500 72 psi) must be:
For a New swing motor ... 20 liter/min (5.3 U.S. gpm)
For a Rebuilt swing motor ... 23 liter/min (6.1 U.S. gpm)
Travel Motor
(1) Connector. (2) Drain hose.
To check the travel motor performance, measure the amount of 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 drain hose (2) from connector (1). Install a plug (3/4-16UN) in the open end of drain hose (2).
3. Connect one end of the vinyl hose to connector (1) and put the other end of the vinyl hose into a suitable
measuring container.
4. Start and run the engine at no-load high idle speed of 1860 50 rpm with the power mode selector switch
at Mode III position.
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Visual Checks
A 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 air vent plug and release
the pressure before the filler cap 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.
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 5700 mm (18 ft 8 in) boom, 2900 mm (9 ft 6 in)
stick, and SAE 0.8 m3 (1 yd3) bucket.
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NOTE: The power mode selector switch must be placed at Mode III position, unless otherwise specified,
during tests.
1. Engine speed:
Excavator with no load at high idle, 1860 50 rpm
Test Preparation:
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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.
4. Draw a 25 m (82.5 ft) straight line on travel test ground as a reference line.
5. 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.
6. 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:
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NOTE: The following chart represents the travel deviation from the reference line:
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:
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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
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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:
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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.
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.
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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.
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2. Measure the time needed to swing the upper structure 90 counterclockwise. Do the same for a 90 swing
clockwise.
3. Put marks on the inner and outer races of the swing bearing.
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3. Put marks on the inner and outer races of the swing bearing.
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Cylinder Drift
Test Preparation:
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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.
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Test Preparation:
1. Place the machine on level ground.
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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.
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Retraction test;
Measure the time required for the stick cylinder to reach full retraction position from full extension position.
Retraction test;
Measure the time required for the bucket cylinder to reach full retraction position from full extension
position.
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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.
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Pump Compartment
(1) Hose.
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 hose (1).
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.
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Adjustment Procedures
NOTE: Values given above are approximate. Use a pressure gauge for adjustment.
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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. Release the pressure in the hydraulic system. See
the section in this module, "Release Of Pressure In The Hydraulic System".
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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).
NOTE: Always make final pressure adjustments on pressure rise.
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).
NOTE: Rod end line relief valves of boom, stick, and bucket are located under the main control valves.
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Pump Compartment
(1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).
Preparation
1. Start Service Program "Calibration Mode" and maintain power shift pressure at 2250 kPa (330 psi). Read
the pressure gauge at tap (1) for the power shift pressure settings.
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NOTE: During this test, to prevent a change in power shift pressure do not turn the engine start switch to
OFF position.
2. Block forward left travel, by putting stopper (16) in position on the gear of sprocket (15), 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 44 5 Nm (32 4 lb ft).
NOTE: Always make final pressure adjustments on pressure rise.
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 (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 (3) to read the pressure.
7. After completion of adjustment, stop the function of the service program "Calibration Mode". Refer to the
section "Calibration Mode Stop Procedure".
Swing Motor Relief Valve Pressure Adjustment (Machines With Swing Lock Pin)
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 and run the engine at no-load high idle speed of 1860 50 rpm with the power mode selector switch
at Mode III position.
5. Increase the hydraulic oil temperature to 55 5C (131 9F).
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6. Place the swing lock pin in the LOCKED position (if equipped), or engage the swing brake.
Adjustment Procedure
1. Slowly move the swing control lever for a full RIGHT swing operation and check the pressure of relief
valve (22).
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 24 000 490 kPa (3500 72 psi). Turning plug (25) clockwise
increases the pressure and turning plug (25) counterclockwise decreases the pressure.
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 (23).
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.
Swing Motor Relief Valve Pressure Adjustment (Machines Without Swing Lock Pin)
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 and run the engine at a no-load high idle speed of 1860 50 rpm with the power mode selector
switch at Mode III position.
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Preparation
1. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic
System".
2. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (3).
3. Start the engine and place the engine speed dial at position "10" with the power mode selector switch at
Mode III position.
4. Increase the hydraulic oil temperature to 55 5C (131 9F).
Adjustment Procedure (In Travel Operation)
1. Block forward left travel by putting stopper (16) in position on the gear of sprocket (15).
Pump Compartment
(1) Tap (power shift pressure). (2) Tap (front pump). (3) Tap (rear pump).
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 (4950
72 psi). Tighten locknut (7) to a torque of 59 10 Nm (44 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).
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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 Nm (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.
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Reference: Turning screw (31) clockwise increases the pressure and turning screw (31) counterclockwise
decreases the pressure.
3. Tighten locknut (30) to a torque of 16 1 Nm (12 1 lb ft).
NOTE: Always make final pressure adjustments on pressure rise.
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 (rear pump).
3. Install 49 000 kPa (7100 psi) pressure gauge at tap (1) of the rear pump.
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4. Install 4900 kPa (700 psi) pressure gauge at tap (29) of pilot oil manifold.
5. Disconnect signal line (32) from the travel motor. Install tee (9U7845) on the port that the signal line was
removed from and connect signal line (32) to tee. Attach nipple (6V3965) and O-ring seal (3J1907) to tee
and install 4900 kPa (700 psi) pressure gauge to the nipple.
6. Start the engine and raise the hydraulic oil temperature to 55 5C (131 9F).
7. Place the power mode selector switch in power Mode III position and maintain the maximum no load
speed of 1860 50 rpm with AEC switch OFF.
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).
Adjustment Procedure
1. While reading the pressure gauges connected to the signal pressure line (32) and to tap (1), slowly move
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the left travel control lever/pedal to the FORWARD position. When the pressure at tap (1) reads 30 600
1180 kPa (4450 170 psi), the pressure gauge connected to signal line (32) 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 (32) does not read 0 kPa (0 psi) at the time the system
pressure at tap (1) reads 30 600 1180 kPa (4450 170 psi), then adjust automatic travel speed change
valve (6) as follows:
NOTE: Always make final pressure adjustments on pressure rise.
a. Loosen locknut (8) and turn screw (7) until the pressure gauge connected to line (30) reads 0 kPa (0
psi) when the pressure gauge at tap (1) reads 30 600 1180 kPa (4450 170 psi).
b. Tighten locknut (8) to a torque of 16 1 Nm (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 15 300 490 kPa (2200 72 psi). Now the pressure gauge connected to signal line (32) 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.
Controller Compartment
(1) Controller alarm lamp. (2) Controller.
Right Console
(3) Monitor. (4) Monitor panel.
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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.
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Illustration Of Flow Meter Tool Layout 1 (Hydraulic Horsepower Control Test) (Main Pumps)
(1) Sleeve. (2) Reusable coupling. (3) O-ring seal. (4) Coupler. (5) Nipple. (6) Plug. (7) O-ring seal. (8) Bolt. (9) Washer. (10)
Adapter. (11) Flange. (12) Hose. (13) Delivery line (front pump). (14) Delivery line (rear pump). (15) Rectangular seal. (16)
Cover. (17) Fitting. (18) Front pump. (19) Rear pump. (20) Adapter. (21) O-ring seal. (22) Coupling assembly. (23) O-ring seal.
(24) Tee. (25) Return line. (26) Portable Hydraulic Tester. (27) Swing motor.
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Circuit Diagram For Flow Test (Hydraulic Constant Horsepower Control) (Front Pump)
(12) Hose. (13) Delivery line (front pump). (14) Delivery line (rear pump). (16) Cover. (18) Front pump. (19) Rear pump. (24)
Tee. (26) Portable hydraulic tester (flow meter). (27) Swing motor. (28) Main control valves. (29) Tap (front pump). (30) Gauge.
(31) Gauge. (32) Tap (power shift pressure). (33) Tap (rear pump). (34) Multitach.
Pump Compartment
(12) Hose. (13) Delivery line (front pump). (18) Front pump. (19) Rear pump. (29) Tap (front pump). (32) Tap (power shift
pressure). (33) Tap (rear pump).
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Circuit Diagram For Flow Test (Hydraulic Constant Horsepower Control)(Rear Pump)
(12) Hose. (13) Delivery line (front pump). (14) Delivery line (rear pump). (16) Cover. (18) Front pump. (19) Rear pump. (24)
Tee. (26) Portable hydraulic tester (flow meter). (27) Swing motor. (28) Main control valves. (29) Tap (front pump). (30) Gauge.
(31) Gauge. (32) Tap (power shift pressure). (33) Tap (rear pump). (34) Multitach.
Pump Compartment
(12) Hose (rear pump charge line). (14) Delivery line (rear pump). (19) Rear pump. (32) Tap (power shift pressure). (33) Tap
(rear 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 rear pump (19).
a. Disconnect delivery line (14) from rear pump (19).
b. Install cover (16), rectangular seal (15), flange (11), bolt (8), and washer (9) to the end of delivery line
(14).
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Test Procedure
NOTE: Perform the front and rear pump flow tests one at a time.
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NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To get more accurate
test results, each of measurements should be corrected by calculating as follows.
Flow corrected = (Flow measured 1800) 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.
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Illustration Of Flow Meter Tool Layout 1 (Negative Flow Control Test) (Main Pump)
(1) Sleeve. (2) Reusable coupling. (3) O-ring seal. (4) Coupler. (5) Nipple. (6) Plug. (7) O-ring seal. (8) Bolt. (9) Washer. (10)
Adapter. (11) Flange. (12) Hose. (13) Delivery line (front pump). (14) Delivery line (rear pump). (15) Rectangular seal. O-ring
seal. (16) Cover. (17) Fitting. (18) Front pump. (19) Rear pump. (20) Adapter. (21) O-ring seal. (22) Coupling assembly. (23)
O-ring seal. (24) Tee. (25) Return line. (26) Portable Hydraulic Tester. (27) Swing motor.
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Pump Compartment
(12) Hose. (13) Delivery line (front pump). (18) Front pump. (19) Rear pump. (29) Tap (front pump). (32) Tap (power shift
pressure). (33) Tap (rear pump).
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g. Connect two tees (40) together using and O-ring seal (46). Install one end of the tees to negative
flow control line (36) port of front pump (18). Install nipple (45) and O-ring seal (7) in each tee (40).
Connect test hose [thread size: 11/16-16UN, 1 m (3.3 ft) long](42) and two coupler assemblies (48)
between nipple (45) on one tee and tap (39) of pilot oil manifold (38).
h. Install 4900 kPa (700 psi) pressure gauge (41) to nipple (45) on the second tee. Install cap (47) and
O-ring seal (46) on the open end of second tee (40). Install pressure gauge (30) at front pump tap (29).
[A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (30)]. Tap (41) is
used to measure the negative control flow. Taps (30) are used to measure the front pump and rear
pump delivery pressure.
i. Install multitach group (34) on the engine. 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 1860 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 5C (131 9F). To increase the oil temperature, move the
stick IN and OUT its full travel several times.
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Pump Compartment
(12) Hose (rear pump charge line). (14) Delivery line (rear pump). (19) Rear pump. (32) Tap (power shift pressure). (33) Tap
(rear 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 rear pump (19).
a. Disconnect delivery line (13) from rear pump (19).
b. Install cover (16), O-ringrectangular seal (15), flange (11), bolt (8), and washer (9) to the end of delivery
line (14).
c. Disconnect return line (25) from swing motor (27).
d. Install tee (24) and two O-ring seals (23) to the swing motor (27) return port. Connect return line (25) to
tee (24).
e. Connect portable hydraulic tester (26) between rear pump (19) and tee (24) with two hoses (12).
f. Remove negative flow control line (36) from port of front pump (18) and install plug (37) and O-ring seal
(46) in open end of negative flow control line (36).
g. Connect two tees (40) together using and O-ring seal (46). Install one end of the tees to negative flow
control line (43) port of rear pump (19). Install nipple (45) and O-ring seal (7) in each tee (40). Connect test
hose [thread size: 11/16-16UN, 1 m (3.3 ft) long](42) two coupler assemblies (48) between nipple (45) on
one tee and tap (39) of pilot oil manifold (38).
h. Install 4900 kPa (700 psi) pressure gauge (41) to nipple (45) on the second tee. Install cap (47) and O-ring
seal (46) on the open end of second tee (40). Install pressure gauge (30) at rear pump tap (33). [A 49 000
kPa (7100 psi) pressure gauge can be used in place of pressure gauge (30)]. Tap (41) is used to measure the
negative control flow. Taps (30) are used to measure the front pump and rear pump delivery pressure.
i. Install multitach group (34) on the engine. This is used to read engine speed.
Test Procedure
NOTE: Perform the front and rear pump negative flow control tests one at a time.
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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 1800 rpm. To get more accurate
test results, measured flow should be corrected by calculating as follows:
Flow corrected = (Flow measured 1800) rpm measured
NOTE: Flow measurements must be taken only in pressure rise.
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Main Pump
(1) Setscrew (second stage constant horsepower control). (2) Shim (first stage constant horsepower control). (3) Shim (Negative
control flow adjustment). (4) Setscrew (maximum flow adjustment).
Output flow adjustment procedure for the front and rear pumps are the same.
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1. Use setscrew (4) for maximum flow regulation. A quarter turn of setscrew (4) changes the flow rate
approximately 6 liter/min (1.6 U.S. gpm) at a pressure of 9800 kPa (1425 psi).
2. Turn setscrew (4) until adjusted to the correct specification.
Turning setscrew (4) clockwise increases the flow rate. Turning setscrew (4) counterclockwise decreases the
flow rate by the same amount as shown in the clockwise rotation.
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