SERV7107-05

Vol. 5, No. 1
May 2007

GLOBAL SERVICE LEARNING

TECHNICAL PRESENTATION

300D SERIES HYDRAULIC

EXCAVATORS - TIER III ENGINES
PILOT HYDRAULIC SYSTEM
(Includes 320D, 321D, 323D, 324D, 325D,
328D, and 330D)

New Product Introduction

(NPI)
300D SERIES HYDRAULIC
EXCAVATORS - TIER III ENGINES
PILOT HYDRAULIC SYSTEM (INCLUDES 320D, 321D,
323D, 324D, 328D, AND 330D)
AUDIENCE
Level II - Service personnel who understand the principles of machine systems operation,
diagnostic equipment, and procedures for testing and adjusting.

CONTENT
This presentation provides an introduction and describes the components and systems operation
of the 300D Series pilot hydraulic system. Additional presentations will cover the machine
walkaround, engines, pumps and controls, main control valve group, swing system, travel
system, and tool control systems in more detail. This presentation may be used for self-paced
and self-directed training.

OBJECTIVES
After learning the information in this presentation, the technician will be able to:
1. identify the components and explain the operation of the 300D Series hydraulic
excavators pilot system, and
2. diagnose problems in the pilot system.

REFERENCES
320D Hydraulic Excavator Specalog AEHQ5856
323D L and 323D LN Hydraulic Excavators HEHH3327
324D Hydraulic Excavator Specalog AEHQ5663
325D Hydraulic Excavator Specalog AEHQ5665
328D Hydraulic Excavator Specalog AEHQ5706
330D Hydraulic Excavator Specalog AEHQ5667
NPI "325D Hydraulic Excavator - Introduction" SERV7105-12
NPI "330D Hydraulic Excavator - Introduction" SERV7106-02
Machine Monitoring System - Systems Operation RENR8068
Self-study "300D Series Hydraulic Excavators, 345C Hydraulic Excavator,
and 365C & 385C Large Hydraulic Excavators SERV7032
iTIM " '300C' Series Hydraulic Excavators-Electronic Control Systems" SERV2693
iTIM "325C Hydraulic Excavators-Hydraulic Systems" SERV2701
325D Hydraulic Schematic KENR6157

Estimated Time: 45 minutes

Illustrations: 19
Form: SERV7107-05
Date: May 2007: Vol. 5, No. 1
© 2007 Caterpillar Inc.
SERV7107-05 -3- Text Reference
Vol. 5, No. 1

TABLE OF CONTENTS

INTRODUCTION ........................................................................................................................5
Pilot Manifold .........................................................................................................................8
Hydraulic Activation Lever ..................................................................................................13
Pilot Controls and Valves ....................................................................................................15

CONCLUSION...........................................................................................................................23
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PREREQUISITES
"Fundamentals of Mobile Hydraulics Self Study Course" TEMV3002
"Fundamentals of Power Train Self Study Course" TEMV3003
"Fundamentals of Electrical Systems Self Study Course" TEMV3004
"Fundamentals of Engines Self Study Course" TEMV3001

NOTES
SERV7107-05 -5- Text Reference
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PILOT HYDRAULIC SYSTEM

Stick Cylinder
Bucket Cylinder Boom Cylinders

Swing Motor Travel Motors

Main Control Valve Group

Pilot
Control
Valves

Priority
Pilot Manifold Valves
Main
Pilot M
Hydraulic
Pump
Pumps
Fan
Fan Pump
Motor
Tank

The Fan Motor and Pump is only used on the !!,

INTRODUCTION

The oil delivered from the pilot pump performs the following main functions.
- Provides pilot oil pressure to the pilot control valves for implements, swing and travel in
order to perform machine operations.
- Creates pilot oil pressure in order to control the output flows of the main pumps.
- Creates pilot oil pressure in order to automatically operate the control devices.

The pilot circuit is classified into the following circuits and each circuit performs one of the
above functions.
- pilot control valve circuit - power shift pressure system
- pressure switch circuits - straight travel valve circuit
- swing parking brake - boom priority
- swing priority - automatic travel speed change
- heavy lift setting of the main relief valve

This section of the presentation will cover the focus on the pilot manifold, the implement
joysticks, and the travel pilot valves.
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3
1 4
5

A gear-type pilot pump (1) oil flow to the pilot system. The pilot pump is mechanically
connected to the drive pump.

The oil delivery from the pilot pump flows through the pilot oil filter (2) and into the
components in the pilot system.

Pilot relief valve (3) is located on the mounting base for the pilot oil filter. The pilot relief
valve limits the pressure in the pilot system. The pilot relief valve setting is adjustable.

Pilot system pressure can be checked at the test port (4) on the right side of the filter base.
Next to the pilot pressure test port is the hydraulic system S•O•S port (5).
SERV7107-05 -7- Text Reference
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PILOT SYSTEM FILTER

FILTER RELIEF VALVE
AND
PILOT SYSTEM
RELIEF VALVE
Pilot System
Relief Valve

Pilot Filter
Relief Valve
Pilot System
Filter

Pilot System
Relief Valve

Pilot System Pilot Filter

Filter Relief Valve
SOS

The filter element in the pilot oil filter removes contaminants from the pilot oil.

If the pilot oil is extremely cold or if the flow of pilot oil through filter element becomes
restricted by contaminants, the oil bypasses the filter element through the bypass relief valve.

The bypass relief valve is built into the base for the pilot oil filter.

The pilot oil flows from the pilot pump to inlet port. When the pressure in the pilot oil system
reaches the pressure setting of the pilot relief valve, part of the pilot oil flow is returned to the
hydraulic tank. The pressure of the pilot system oil in outlet lines is equal to the pressure
setting of the pilot relief valve.
SERV7107-05 -8- Text Reference
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Pilot Manifold

The pilot manifold is the same as the "300C" pilot manifold. The pilot manifold is accessible
by removing the cover plate under the machine, behind the swing bearing. The manifold is
located directly below the main control valve.

The hydraulic activation valve (1) and solenoid (2) are located in the pilot manifold along with
the swing brake solenoid (3) and the two-speed travel solenoid (4).
SERV7107-05 -9- Text Reference
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PILOT MANIFOLD
LOCKED - HIGH SPEED TRAVEL Tank
SWING BRAKE ENGAGED Hydraulic
Activation
Straight Valve
Travel
Solenoid Pilot Heavy Lift Pilot
Hydraulic
Pump Solenoid Valves
Activation Valve
Travel Pilot Pump
Motors

Two Speed
Travel
Swing
Solenoid
Brake
Solenoid
Hydraulic Implement
Activation Hydraulic
Swing Valve
Priority Lockout
Valve Solenoid

Check
Valve

Swing
Brake

Oil from the pilot pump enters the pilot manifold to be distributed to the various components of
the machine. Some of the pilot oil flow is directed to the swing priority valve, to the two speed
travel solenoid valve, and to the straight travel solenoid valve. The rest of the pilot oil flows
through the check valve.

Two Speed Travel Solenoid Valve: The two speed travel solenoid valve controls oil flow to
the of the two-speed travel motors. In the illustration above the solenoid is energized. Pilot oil
is directed to the travel motors to shift displacement change valves (not shown). When the
displacement change valves shift, the motors will destroke for higher speed.

Check Valve: The pilot manifold also contains a check valve. The check valve maintains pilot
accumulator pressure in the pilot circuit when the engine is not running. By maintaining the
pilot pressure (for a limited time) when the engine is stopped, the implements can be lowered
safely to the ground.
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Pilot Accumulator: The pilot accumulator is used to release the swing brake and for lowering
the boom and stick in the event of a loss of pilot system pressure or a dead engine. The pilot
accumulator also helps to dampen pressure spikes in the pilot system, which enhances the
stability of the machine control systems.

The accumulator stores pilot pressure oil for use at the main control valves. During some
operations, the pilot system needs more oil because there is insufficient flow from the pilot
pump.

Implement Hydraulic Lockout Solenoid Valve and Hydraulic Activation Valve: These two
valves work together to either prevent the implement control valves and the motors from being
activated or to allow them to be activated. In the de-energized position, no pilot oil is available
to operate the implements. Pilot oil is blocked at both valves.

When the hydraulic lockout control lever in the cab is in or moved to the LOCKED position,
the plunger of the limit switch is not depressed by the control lever. The limit switch is in the
OFF position.

When the hydraulic activation control lever is in the LOCKED position, the hydraulic
activation solenoid is not energized.

The spool is held up by a spring. The spool blocks the pilot supply oil from going to the pilot
valves. The spool also opens a passage to drain from the pilot valves to the tank.

In the locked position, if the joysticks are moved, the cylinders and the motors cannot be
activated.

Swing Brake Solenoid Valve: The swing brake solenoid valve energizes to release the spring-
applied, hydraulically-released wet disc swing brake. The swing brake is automatically
released when any joystick function is performed by the operator. With the swing brake
solenoid valve de-energized, the swing brake is engaged by springs.
SERV7107-05 - 11 - Text Reference
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Implement Hydraulic
PILOT MANIFOLD Lockout Solenoid

UNLOCKED - SWING BRAKE RELEASED Tank

Hydraulic
Activation
Valve
Straight
Travel Hydraulic
Solenoid Pilot Heavy Lift Pilot Activation Valve
Pump Solenoid Valves
Pilot Pump
Travel
Motors

Two Speed
Travel
Swing
Solenoid
Brake
Solenoid
Hydraulic Implement
Activation Hydraulic
Swing Valve
Priority Lockout
Valve Solenoid

Check
Valve

Swing
Brake

When the hydraulic lockout control lever in the cab is placed in the UNLOCKED position, the
limit switch closes the circuit path and the lockout solenoid valve is energized.

When the implement hydraulic lockout solenoid valve is energized, pilot oil is directed to move
the hydraulic activation valve down. Pilot oil flows through the hydraulic activation valve to
the swing brake solenoid valve, the left and right joysticks, and the travel pilot valves. The
hydraulic activation valve also supplies pilot oil for the heavy lift solenoid valve.

When a implement is activated the swing brake solenoid is energized by the Machine ECM.
Pilot oil is directed through the swing brake solenoid valve to release the swing park brake in
the swing motor group.
SERV7107-05 - 12 - Text Reference
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The pilot accumulator (arrow) provides pressure oil to the pilot system when the pilot pump
flow is low or the pilot pump has stopped.

Low pilot oil flow to the pilot system may be caused by the following two reasons:

- Implements are lowered while the engine is stopped and oil supply to the main control
valves is stopped.

- Combined implement/swing/travel operations.

SERV7107-05 - 13 - Text Reference
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Hydraulic Activation Lever

The hydraulic lockout lever (arrow) is shown in the LOCKED position.

The engine will not start unless the hydraulic activation lever (3) is in the LOCKED position.

Raise the lever activation lever to the UNLOCKED position to energize the implement
hydraulic lockout solenoid valve to allow the operator to move the implements.

If the machine is running, the operator can lockout the implement controls by returning the
lever to the LOCKED position.
SERV7107-05 - 14 - Text Reference
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HYDRAULIC
ACTIVATION LEVER

Hydraulic Activation
Lever

Lever Plunger Limit Switch

A limit switch and plunger are located on a bracket with hydraulic lockout lever.

When the hydraulic activation control lever is moved forward, the lever pushes the plunger
down to activate the limit switch.

When the hydraulic lockout control lever is shifted to the rear to the LOCKED position, the
implement lockout solenoid valve is not energized, so the hydraulic activation valve does not
shift to direct pilot oil to the pilot control valves.

The joysticks and/or travel pedals can not shift a control valve in the main control valve group
when the hydraulic activation lever is in the locked position.
SERV7107-05 - 15 - Text Reference
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4
3

1 8
6
5 2
7

10
9

10

Pilot Controls and Valves

Pilot controls in the cab include:

- left (1) and right (2) travel pedals
- left (3) and right (4) travel levers
- auxiliary foot switch (5) (attachment)
- straight travel (6) (attachment)
- left joystick (7) to control the swing and stick (SAE excavator pattern)
- right joystick (8) to control the bucket and boom (SAE excavator pattern)
- foot rest (9 and 10)

The joysticks shown above are equipped with full electronic control for the tool control system.

NOTE: The switch for one touch low idle is on the right joystick. If the machine is
equipped with a magnet, the trigger switch on the front of the right joystick turns the
magnet on, while the trigger switch on the front of the left joystick turns the magnet off.
SERV7107-05 - 16 - Text Reference
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11

The resolver block (1) is located under the cab. The resolver block provides a junction from
pilot lines to the joystick to the main control valve group as well as sensing when an implement
or the swing is activated.

The resolver network in the block, directs the pilot signal pressure to the swing/implement
pressure switch (2) for Automatic Engine Control (AEC).

Two travel pressure switches (not shown) and the swing/implement pressure switch (2) are
activated by pilot pressure oil. The switches close at 490 ± 49 kPa (71 ± 7 psi) and open at
290 ± 0 kPa (42 ± 0 psi).

The pressure switches are inputs to the Machine ECM. The Machine ECM uses these inputs to
tell when a hydraulic function has been activated.

If Automatic Engine Control (AEC)/one touch low idle is activated and the machine is at low
idle the Machine ECM will increase the engine speed to the current speed dial setting.

When only the swing/implement pressure switch is activated, the Machine ECM will release the
swing brake. When all three pressure switches are activated at the same time, the Machine
ECM will energize the straight travel solenoid.
SERV7107-05 - 17 - Text Reference
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Travel Pilot Valves

Pilot Manifold
IMPLEMENT PILOT
Travel Pilot Valves
JOYSTICKS

Stick Swing Bucket Boom

OUT IN R L OPEN CLOSE DOWN UP

Resolver
Swing/Implement Block
Pressure
Switch

aR3 aR4 bR3 bR4 bL3 bL2 bL4 aL2

12

When one or more of the joysticks are shifted, resolvers in the block direct the highest pilot oil
pressure to the the swing/implement pressure switch.

The Machine ECM will cause the engine to increase rpm to match the speed dial position.
SERV7107-05 - 18 - Text Reference
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PILOT CONTROL VALVE

SECTION A-A
Pilot Pilot
Manifold Manifold
Joystick

Plate

Rod
Metering
Spring

Seat

Port A Port B
Return
Return Spring
Chamber
A Spool
Supply
Pilot Oil
A

Port A Port B

13

When the pilot joystick lever is shifted, the joystick contacts the rod and pushes it down against
its spring. The rod will contact the spool and move it down against its spring. Depending on
how far the lever is moved, determines how far the spool moves.

As the spool moves down, the spool will close off the drain passage for the oil to the control
valve and meter pilot pressure oil to the control valve to cause the control spool (not shown) to
shift. The greater the pilot oil flow to the control spool, the greater the control spool travel.

As pressure increases in the pilot line to the control valve, the pressure moves the spool up to a
balance position against the spool and metering springs to maintain a constant pilot pressure in
the pilot line. This action will maintain the position of the control spool in the control valve
until the joystick is moved.

In summary, once the pilot lever is shifted, the pilot valve becomes a pressure reducing valve
which maintains a downstream pressure equal to the spring forces above the spool.

When the joystick is released, the joystick will return to the NEUTRAL position due to the
force of the return spring moving the spool back up. When this occurs, the pilot oil is blocked
by the spool from flowing to the control valves to shift the spool and pilot oil at the control
spool is drained to the tank past the spool.
SERV7107-05 - 19 - Text Reference
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TRAVEL PILOT CONTROL VALVE

Pedal

Rod
Dampening
Piston Pilot Supply

Left Right
Dampening Orifice
Piston Check
Valve

Tank

Metering
Spring Spool

REV FWD FWD REV

Return Pilot
Spring Supply aL1 bL1 bR1 aR1

Travel Pressure
Resolver
Switch (AEC)
Travel Travel
Valve Valve

14

The travel pilot control valve operates similar as the implement pilot valves.

Depending on how far the the travel pedal or lever is moved, will determine the amount of
pilot oil directed to the respective travel control valve.

A dampening function is built into the travel pilot control valve which allows the operational
speed of the travel lever/pedal to correspond to the movement of the operator's foot. The
dampening function also prevents the vibration that occurs when the travel lever/pedal is
released.

When the travel lever/pedal is moved suddenly from the NEUTRAL position, the rod is pushed
downward. The rod moves the dampening piston downward. The hydraulic oil below the
dampening piston is pressurized. An orifice check valve allows the trapped hydraulic oil below
the dampening piston to gradually flow into into the metering spring chamber, which is open to
the tank. The gradual flow of oil through the orifice check valve provides the dampening
function.
SERV7107-05 - 20 - Text Reference
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PWM SOLENOID VALVE

PWM SIGNAL INCREASE PWM SIGNAL DECREASE

Solenoid

Plunger
Spring Spring

Tank Tank

Control Spool Control Spool

Pilot Oil Pilot Oil

15

The attachment circuits are controlled by proportional solenoids valves. The valves receive
PWM signals from the Machine ECM to shift energize the solenoid. Depending on the amount
of current sent will determine how far the solenoid shifts the control spool.

Pilot oil is directed to and from the attachment circuits to control the position of the control
spool for the attachment.

NOTE: The solenoid valves also act as variable pressure reducing valves. Instead of
using a spring to control the downstream pressure, the current is varied to the solenoid
to control the downstream pressure to the control spool. For a fixed current the pilot
pressure to the spool is maintained as it was for the joysticks.
SERV7107-05 - 21 - Text Reference
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16

When the joysticks are operated, the pilot control valves send pilot pump oil through the pilot
lines to the pilot ports (arrows) at the main control valve group in order to shift the spools in the
main control valve.

Additional pilot lines are located below the main control to shift the control spools in the
opposite direction.
SERV7107-05 - 22 - Text Reference
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Load Check
Valve
CONTROL VALVE
FULL SHIFT
Port A Port B
Parallel Feeder
Passage

Pilot Valve
or
Solenoid

Center Bypass
Passage

17

Pilot oil enters a control valve from either end to shift the main control spool.

The control spool will shift in proportion to the amount of pilot oil sent to the control spool
from the pilot valve or solenoid.

For some circuits, proportional solenoid valves are used to direct pilot oil to shift the control
spool.
SERV7107-05 - 23 - Text Reference
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18

CONCLUSION

This presentation has provided information for the Caterpillar 300D Series Hydraulic
Excavators.

This presentation covered the pilot control system and pilot control valves.

Additional presentations are available for each system used on these machines.

When used in conjunction with the service manual, the information in this package should
permit the technician to do a thorough job of analyzing a problem in these systems.

For service repairs, adjustments, and maintenance, always refer to the Operation and
Maintenance Manual, Service Manuals, and other related service publications.