330D-336D Testing and Adjusting (RENR9585-11) PDF

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Testing and Adjusting
330D and 336D Excavators Hydraulic System
Media Number -RENR9585-11 Publication Date -01/09/2008 Date Updated -23/09/2008
i02662145
General Testing and Adjusting Information

SMCS - 5050
Hydraulic oil pressure can remain in the hydraulic

systems after the engine and pump have been
stopped. Serious injury can be caused if this pressure
is not released before any service is done on the
hydraulic systems. To prevent possible injury, refer to
the section, Testing and Adjusting, "Hydraulic
System Pressure - Release" before any fitting, hose or
component is loosened, tightened, removed or
adjusted.
When possible, the work tool must always be lowered

to the ground before service is started. When it is
necessary for the boom to be in the raised position
while tests or adjustments are done, be sure that the
boom, stick and work tool have correct support.
The swing lock (if equipped) must be engaged before

service is started.
Always move the machine to a location away from the

travel of other machines. Be sure that other personnel
are not near the machine when the engine is running
and tests or adjustments are being made.
The correct oil temperature, flow, and pressure are necessary for correct operation. Pump output (oil flow) is a
function of engine speed (rpm) and valve adjustment. Oil pressure is caused by resistance to the flow of oil.
Visual checks and measurements are the first steps during troubleshooting. Refer to Testing and Adjusting,
"Visual Inspection". Next, perform the operational checks. Refer to Testing and Adjusting, "Operational Checks".
Finally, perform the required tests and adjustments on the machine.
Copyright 1993 - 2009 Caterpillar Inc. Sat Aug 29 13:49:28 UTC+0300 2009
All Rights Reserved.
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Visual Inspection
SMCS - 5050-040
A visual inspection of the system is the first step in order to troubleshoot a problem. Shut off the engine and lower
all implements to the ground before performing the visual inspection.
1. Check the oil level in the hydraulic tank. Slowly loosen the fill/vent plug and release the pressure before the
fill/vent plug is removed.
NOTICE
Care must be taken to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting and repair of the
product. Be prepared to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Refer to Special Publication, NENG2500,

"Caterpillar Tools and Shop Products Guide" for
tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations

and mandates.
2. Remove the hydraulic filter elements. Inspect the hydraulic filters for material that would give an indication
of damage to a component.
3. Inspect all lines and connections for damage or leaks.
4. Inspect control linkages for bent components, broken components or damaged components.
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i01246594
Hydraulic System Pressure - Release

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

z Travel hydraulic circuit
z Attachment hydraulic circuits (if equipped)
z Pilot hydraulic circuit
z Return hydraulic circuit
Note: Refer to the Disassembly and Assembly Manual for additional information concerning service of the
components of specific hydraulic circuits.
Release Of Hydraulic Pressure From A Single Hydraulic Circuit
Personal injury can result from hydraulic oil pressure

and hot oil.

system after the engine has been stopped. Serious
injury can be caused if this pressure is not released
before any service is done on the hydraulic system.
Make sure all of the attachments have been lowered

to the ground, and the oil is cool before removing any
components or lines. Remove the oil filler cap only
when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE

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and mandates.
Perform the following Steps in order to release the hydraulic pressure from a single hydraulic circuit of the main
hydraulic system.
1. Position the machine on level ground.
View Image
Illustration 1 g00666865
2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the
ground. Lower the boom until the bucket is flat on the ground. Refer to Illustration 1.
3. Shut off the engine.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL STROKE
positions. This will release the high pressure only in that single hydraulic circuit. This will also release any
pressure that might be present in the pilot hydraulic circuit.
Note: If the desired hydraulic circuit that requires service requires the activation of a switch for operation,
activate the necessary switches for the operation of the hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Turn the engine start switch to the OFF position.
9. Slowly loosen the filler plug on the hydraulic tank and release the pressure from the hydraulic tank. Leave the
filler plug loose for a minimum of 45 seconds. This will release the pressure that may be present in the return
hydraulic circuit.
10. Tighten the filler plug on the hydraulic tank to the specified torque.
11. The pressure in the single hydraulic circuit that requires service is now released and lines and components
can be disconnected or removed from that hydraulic circuit.
Release Of Hydraulic Pressure From Multiple Hydraulic Circuits

and hot oil.

Make sure all of the attachments have been lowered

to the ground, and the oil is cool before removing any
NOTICE


and mandates.
Perform the following Steps in order to release the hydraulic pressure from multiple hydraulic circuits of the main
hydraulic system.
View Image
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2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the
ground. Lower the boom until the bucket is flat on the ground. Refer to Illustration 2.
4. Turn the engine start switch to the ON position without starting the engine.
5. Place the hydraulic activation control lever in the UNLOCKED position.
6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL STROKE
positions. This will release the high pressure only in that hydraulic circuit. This will also release any pressure
that might be present in the pilot hydraulic circuit.
Note: If the hydraulic circuit that requires service requires the activation of a switch for operation, activate
the necessary switches for the operation of the hydraulic circuit.
7. Place the hydraulic activation control lever in the LOCKED position.
8. Start the engine.
9. Place the hydraulic activation control lever in the UNLOCKED position. Do not move any joysticks or
pedals from the NEUTRAL position during this step. Do not activate any switches during this Step.
10. Return the hydraulic activation control lever to the LOCKED position.
12. Repeat Steps 4 through 11 for each additional hydraulic circuit that requires service.
13. After releasing the hydraulic pressure in each of the desired hydraulic circuits, place the hydraulic activation
control lever in the LOCKED position.
14. Turn the engine start switch to the OFF position.
15. Slowly loosen the filler plug on the hydraulic tank and release the pressure. Leave the filler plug loose for a
minimum of 45 seconds. This will release the pressure that may be present in the return hydraulic circuit.
16. Tighten the filler plug on the hydraulic tank to the specified torque.
17. The pressure in the multiple hydraulic circuits that require service is now released and lines and components
can be disconnected or removed from those hydraulic circuits.
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i02843821
Main Hydraulic Pump Air - Purge

SMCS - 5070-542-AI
When the main pumps have been serviced or the hydraulic oil has been replaced, remove the air from the main
pump. Remove the air from the main pump in the following manner:
NOTICE

"Caterpillar Dealer Service Tool Catalog" for tools
and supplies suitable to collect and contain fluids on
Caterpillar products.

and mandates.

and hot oil.

Make sure all of the work tools have been lowered to

the ground, and the oil is cool before removing any
View Image
Pump compartment
(1) Plug
(2) Case drain hose
(3) Pressure tap
1. While the engine is stopped, remove plug (1) .
2. Fill the main pumps with oil.
3. Install plug (1) . Tighten plug (1) securely.
NOTICE
To avoid system damage, make sure that the
hydraulic pump is properly filled with hydraulic oil
before start-up.
5. Place the engine at low idle position. Raise the boom and hold the boom in this position.
6. Slowly loosen case drain hose (2) until oil begins to flow around the hose connection.
7. Tighten case drain hose (2) to the specified torque.
8. Stop the engine and slowly lower the boom until the work tool is on the ground. This pressurizes the
hydraulic tank.
9. Connect 6V-4143 Quick Connect Coupler and 177-7860 Hose Assembly to pressure tap (3) until oil begins
to flow from the open end of the hose.
10. Remove the quick coupler and hose assembly from pressure tap (3) .
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i03108265
Overload Warning - Set - If Equipped

SMCS - 1408; 5472; 7490
The overload warning device is a system that warns the operator that the pump pressure for the boom cylinder
lines has exceeded a set value. The set value for the overload warning device varies because of the machine
configuration and the attachments that are installed. The alarm setting for the overload warning device on your
machine should be checked for the proper adjustment. Use the information that follows in order to calculate the
correct value and reset the parameter for the overload warning device.
Note: The engine speed and/or the machine configuration that is used during this test can affect the results of this
test. Refer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for the engine speed that was
used for this test.
Note: The relief valve pressure settings must be set to the relief valve pressure specification before performing
this operational check. Refer to Testing and Adjusting, "Specifications".
Calculation Of The Threshold Pressure For The Overload Warning

Device
Use the information that follows in order to calculate the correct value of the threshold pressure for the overload
warning device on your machine.
View Image
Basic position of the machine
(A) Full extension of bucket cylinder
(B) Full retraction of stick cylinder
(C) Position of the pin in the boom foot
(D) Position of the track
(E) Secured position of the bucket
(F) Position of the pin in the stick nose
1. Position the machine. Refer to Illustration 1.
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2. Stop the engine.
3. Connect the linkage and a stationary object with a suitable lifting device (E) . Make sure that the pin in stick
nose (F) is the same distance from the ground as the pin for the boom foot (C) .
Note: Make sure that the boom is positioned perpendicular to the track. The machine should be configured
with the boom, the stick, and the attachments that will be used.
5. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer to
Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
6. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
7. Access the "PERFORMANCE" menu with the monitor in order to measure the pump pressure during boom
operation. The "PERFORMANCE" menu allows the user to view data for a list of system parameters. The
data allows the user to monitor machine systems during machine operation. Use Illustration 2 in order to
navigate the monitor.
View Image
(1) Up key
(2) Right key
(3) Home key
(4) Main menu key
(5) Left key
(6) Down key
(7) Cancel key or back key
(8) OK key
8. From the default screen, press the main menu key (4) .
View Image
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Typical example of the "MAIN MENU" for the monitor
9. The "PERFORMANCE" menu option is entered by selecting "PERFORMANCE" from the "MAIN MENU".
Press the left key (5) or the right key (2) until "PERFORMANCE" is highlighted in order to select this
option. Then press the OK key (8) . Refer to Illustration 3.
View Image
Typical example of the "PERFORMANCE" menu for the monitor
10. From the "PERFORMANCE" menu, use the appropriate up key (1) or down key (6) to scroll through the
listed parameters for the system components. Find the parameter for the pump pressure.
View Image
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Position of the machine for the measurement of the pump pressure
(G) Extension of boom cylinder
(H) Track at the rear or the machine
(J) Free space between the track and the ground
11. Slowly extend the boom cylinders. Extend the boom cylinders until the track that is under the rear side of the
machine is above the ground. Refer to Illustration 5.
12. Record the measured pump pressure from the display on the monitor in the cab in Table 1.
13. Slowly retract the boom cylinder. Retract the boom cylinder until the track that is under the rear side of the
machine is on the ground.
14. The value of the threshold pressure for the overload warning device is 70% of the recorded pump pressure
from Step 12. This calculation is shown in Table 1.
Table 1
Calculation for Overload Warning Device (OLWD)

Pump Pressure (PP)
OLWD Pressure = PP x 0.7
Input The Value Of The Threshold Pressure For The Overload

Warning Device
View Image
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(1) Up key
(2) Right key
(3) Home key
(4) Main menu key
(5) Left key
(6) Down key
(7) Cancel key or back key
(8) OK key
1. In order to access the "OVER LOAD WARNING" parameter, you must first enter the "SERVICE" mode on
the monitor.
2. Use the following procedure to access the "SERVICE" screen on the monitor.
a. From the default screen, press the main menu key (4) .
b. From the "MAIN MENU" screen, use the right key (2) to scroll through the menu options.
View Image
c. When the "SERVICE" option is highlighted, press the OK key (8) .
View Image
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d. When "PASSWORD" screen appears, use the right key (2) and the left key (5) in order to scroll through
the characters. When the desired character is highlighted, press the OK key (8) . Enter the password for
service FFF2 in order to continue to the "SERVICE" screen.
e. After the password has been entered the "SERVICE" screen should appear. Refer to Illustration 9.
View Image
Typical example of the "SERVICE" menu for the monitor
3. From the "SERVICE" menu, use the up key (1) or the down key (6) in order to move the highlighted line.
4. When the "CONFIGURATIONS" menu option is highlighted, press the OK key (8) .
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View Image
Typical example of the "CONFIGURATIONS" screen
5. After the OK key (8) is pressed the "CONFIGURATIONS" screen will appear. From the
"CONFIGURATIONS" menu, highlight "PARAMETER SETTING".
6. When the "PARAMETER SETTING" option is highlighted, press the OK key (8) .
View Image
Typical example of the "PARAMETER SETTING" screen
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7. After the OK key is pressed the "PARAMETER SETTING" menu will appear. From the "PARAMETER
SETTING" menu, highlight "OVER LOAD WARNING".
8. When "OVERLOAD WARNING" option is highlighted, press the OK key (8) .
View Image
Typical example of the "OVER LOAD WARNING" screen
9. After the OK key is pressed the "OVER LOAD WARNING" parameter will appear.
View Image
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10. Press the up key (1) or the down key (6) in order to highlight the desired setting to change. Press the OK key
(8) in order to highlight the value of the data.
11. Press the up key (1) or the down key (6) in order to change the value. Press the OK key (8) in order to set the
value into memory.
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i03295969
Operational Checks
SMCS - 5050-535
The operational checks can be used to find leakage in the system and components that are not functioning
correctly. The speed of rod movement or the torque on a motor can be used to check the condition of the
cylinders, motors and the pumps.
Perform the following operational checks in order to troubleshoot problems concerning the hydraulic circuits and
components on the machine.
z Testing and Adjusting, "Engine Performance - Test (Engine Speed)"
z Testing and Adjusting, "Travel on Level Ground - Test"
z Testing and Adjusting, "Travel on Level Ground - Test (Optional Test)"
z Testing and Adjusting, "Machine Drift on a Slope - Check"
z Testing and Adjusting, "Swing Speed and Overswing on Level Ground - Check"
z Testing and Adjusting, "Swing Speed and Swing Drift on a Slope - Check"
z Testing and Adjusting, "Cylinder Drift - Check (Empty Bucket)"

z Testing and Adjusting, "Cylinder Drift - Check (Loaded Bucket)"
z Testing and Adjusting, "Cylinder Speed - Check"
The specifications that are listed in tables for the operational checks are calculated average values. The values will
vary due to the configuration of the machine and engine speed. Table 1 contains the machine configurations that
were used in order to obtain these specifications.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for the specifications for
engine speed.
Table 1
Machine Configuration
Sales Model Boom Stick Bucket
330D
6.5 m (21 feet 4 inches) 3 3
336D 3.2 m (10 feet 6 inches) 1.4 m (1.83 yd )
330D L
336D L 6.5 m (21 feet 4 inches) 3.2 m (10 feet 6 inches) 3 3
1.5 m (1.96 yd )
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i02485052
Engine Performance - Test - Engine Speed

SMCS - 1000-081
Table 1
Required Tools
Part Number Description Qty
9U-7400 Multitach Tool Group 1
2. Stop the engine.
3. Install 9U-7400 Multitach Tool Group on the engine.
6. Read the engine speed display (rpm) on the multitach. Refer to Table 2 for the specifications for engine speed
at the desired engine operation.
Table 2
Specifications
Item
New Rebuild Service Limit
1880 ± 50 rpm (2) 1680 to 1930 rpm (1)

No load high idle (1)
1980 ± 50 rpm (3) 1780 to 2030 rpm (3)
No load low idle 800 ± 50 rpm 800 ± 100 rpm
Maximum speed with load (4) 1720 rpm (5) 1670 rpm (5) 1620 rpm (5)
No load speed (6) 1300 ± 50 rpm 1300 ± 100 rpm

( 1 ) AEC switch in the OFF position
( 2 ) Three seconds after the engine speed dial was placed at position "10"
( 3 ) Engine rpm within three seconds after the engine speed dial was placed at position "10"
( 4 ) Pressure is relieved from both pumps (stall condition).
( 5 ) Minimum
( 6 ) AEC switch in the ON position
Note: A New specification is the performance that can be expected for a new machine. A Rebuild specification is
the performance that can be expected after rebuilding the components of a system. Performance beyond the
Service Limit is an indication of these problems: improper maintenance or adjustment, component wear and
failure.
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i02860870
Travel on Level Ground - Test - Optional Test

SMCS - 4351-081
Note: When the procedure for the Travel On Level Ground cannot be performed, this test may be used as a
substitute.
used for this test. Refer to Testing and Adjusting, "Operational Checks" for the machine configurations that were
used for this test.
Table 1
Required Tools
Description Qty
Stopwatch 1
View Image
4. Raise a track off the ground. Refer to Illustration 1.
5. Put a mark on a shoe of the raised track.
6. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch OFF.
7. Place the travel speed control switch in HIGH position.
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8. Move the travel lever of the raised track to full travel position.
9. Measure the time that is required for the raised track to make three complete revolutions. Measure the time
that is required in each direction.
10. Place the travel speed control switch in the LOW position and repeat Steps 8 through 9.
Table 2
Time For Three Revolutions (time in seconds)

Standard Undercarriage
Travel Speed New Rebuild Service Limit
Forward
HIGH 22.5 or less 23.5 or less 24.5 or less
Reverse
Forward
LOW 34.5 or less 35.5 or less 36.5 or less
Reverse
Table 3
Time For Three Revolutions (time in seconds)
Long Undercarriage
Forward
Reverse
Forward
Reverse
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i02860877
Travel on Level Ground - Test

SMCS - 4351-081
used for this test.
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
View Image
(A) Preliminary run 5 m (16.4 ft)
(B) Travel distance 20 m (65.6 ft)
(C) Bucket height 0.5 to 1 m (1.6 to 3.3 ft)
1. Travel distance must be at least 25 m (82 ft) long. Travel test ground must be hard and as level as possible.
2. Draw a 25 m (82 ft) straight line on travel test ground as a reference line.
4. Place the machine controls at the following settings: Engine speed dial "10" and AEC switch OFF.
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6. The bucket should be empty.
7. Position the machine so that one track is parallel with the reference line. Position the machine for the travel
test. Refer to Illustration 1.
8. Place the travel speed control switch in HIGH position.
9. Move the machine by operating both travel levers at the same time.
10. The first 5 m (16.4 ft) are for a preliminary run. Measure the travel time that is required to travel the
remaining 20 m (65.6 ft). Measure the time that is required in each direction.
11. Measure the travel deviation from the reference line.
12. Place the travel speed control switch on the LOW position and repeat Steps 9 through 11.
Table 2
Travel Time (time in seconds)

Forward
Reverse
Forward
Reverse
Note: The following table represents the travel deviation (distance) from the reference line.
Table 3
Travel Deviation
mm (inch)
Forward
HIGH 800 (31.5) or less 1200 (47.2) or less 1500 (59.1) or less
Reverse
Forward
LOW 800 (31.5) or less 1200 (47.2) or less 1500 (59.1) or less
Reverse
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i02992506
Machine Drift on a Slope - Check

SMCS - 4095-535
Measuring the amount of drift of the machine on a slope will determine if there is a need to check the travel brake.
used for this test.
Table 1
Required Tools
Description Qty
Stopwatch 1
Scale 150 mm (6 inch) 1
View Image
1. Place the machine on a slope of 12 degrees. The surface of the slope must be hard and smooth.
2. Position the implements, as shown. Refer to Illustration 1.
View Image
26
4. To indicate the machine's relative position to the slope, put a mark on both the track and the track roller
frame. Refer to Illustration 2.
5. Stop the engine.
6. Measure the machine movement on the slope after three minutes.
Table 2
Drift mm (inch)
New Rebuild Service Limit
0 0 0
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i02860880
Swing Speed and Overswing on Level Ground - Check

SMCS - 5058-535-ZW
Measuring the swing speed and the overswing of the machine will determine if there is a need to check the swing
motor or the anti-reaction valve. The fine swing control switch (if equipped) must be in the OFF position.
used for this test.
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
View Image
1. Position the machine on level ground. Refer to Illustration 1.
2. Stop the engine.
View Image
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(A) Upper frame
(B) Undercarriage frame
(C) Marking
3. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer race of the
swing bearing. The mark will be used as a target to stop the swing operation. Refer to Illustration 2.
5. Move the swing joystick in either direction until the machine completes a 180 degree swing operation away
from the target.
6. Move the swing joystick in either direction until the machine completes a 180 degree swing operation toward
the target. Return the swing joystick to the NEUTRAL position at the target.
7. Measure the amount of overswing by measuring the distance between the marks on the swing bearing. Refer
to Illustration 2.
Note: Use a point that is visible from the operator seat as a reference point for the target.
Table 2
Overswing
Item New Rebuild Service Limit
Right Swing
1300 mm (51.2 inch) or less
1400 mm (55.1 inch) or less 1600 mm (63.0 inch) or less
Left Swing
8. Move the swing joystick in each direction and measure the time that is required to complete a 180 degree
swing operation.
Table 3
Swing Time (seconds)

Right Swing
4.9 or less 5.4 or less 6.0 or less
Left Swing
Sat Aug 29 13:56:41 UTC+0300 2009

Copyright 1993 - 2009 Caterpillar Inc.
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i02860891
Swing Speed and Swing Drift on a Slope - Check

SMCS - 5058-535-ZW
Measuring the swing speed on a slope will determine if there is a need to check the swing motor and the anti-
reaction valve. Measuring the swing drift on a slope will determine if there is a need to check the swing parking
brake.
used for this test.
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
View Image
1. Complete the following steps in order to measure the swing speed on a slope.
a. The work tool should be empty.
b. Position the machine on a slope of 12 degrees. Refer to Illustration 1.
c. Position the implements at maximum reach and close the work tool. Position the work tool above the
ground so that the work tool will not come in contact with any obstacles.
View Image
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d. Position the upper structure at position (A) . The upper structure should be at a 90 degree angle to the
lower structure. Refer to Illustration 2.
e. Measure the time that is required to swing the upper structure from position (A) to position (B) .
f. Position the upper structure at position (C) . The upper structure should be at a 90 degree angle to the
lower structure.
g. Measure the time that is required to swing the upper structure from position (C) to position (B) .
Table 2
Swing Time (seconds)

Right Swing
5.5 or less 6.3 or less 7.0 or less
Left Swing
2. Complete the following steps in order to measure the swing drift on a slope.
View Image
a. Position the upper structure at position (A) . The upper structure should be at a 90 degree angle to the
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View Image
(A) Upper frame
(B) Undercarriage frame
(C) Marking
b. To indicate the relationship of the two positions, put a mark (C) on the inner race and the outer race of
the swing bearing. Refer to Illustration 4.
c. Stop the engine.
d. Leave the machine in this position for three minutes. Measure the swing drift on the circumference of
the swing bearing.
e. Start the engine.
f. Position the upper structure at position (C) . The upper structure should be at a 90 degree angle to the
g. Repeat Steps 2.b through 2.d.
Table 3
Swing Drift mm (inch)
Right Swing
0 0 0
Left Swing
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i02860897
Cylinder Drift - Check - Empty Bucket

SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 7562-535-D9 ; 7562
used for this test.
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
View Image
Position the machine on level ground. Empty the bucket. Refer to Illustration 1.
Boom Cylinder Head End, Stick Cylinder Rod End, and Bucket
Cylinder Head End
1. Fully extend the bucket cylinder.
2. Fully retract the stick cylinder.
3. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.
View Image
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4. Raise the boom until the stick to bucket pin is the same height as the boom foot pin. Refer to Illustration 2.
5. Measure each cylinder's length from cylinder pin to cylinder pin.
6. Stop the engine.
7. Leave the machine in this position for five minutes. Measure each cylinder's length from cylinder pin to
cylinder pin for drift.
Table 2
Cylinder Drift (Empty Bucket)

Boom Cylinder 6.0 mm (0.24 inch) or less 12.0 mm (0.47 inch) or less 24.0 mm (0.94 inch) or less
Stick Cylinder 10.0 mm (0.39 inch) or less 15.0 mm (0.59 inch) or less 25.0 mm (0.98 inch) or less
Bucket Cylinder
10.0 mm (0.39 inch) or less 15.0 mm (0.59 inch) or less 25.0 mm (0.98 inch) or less
Stick Cylinder Head End

3. Fully extend the stick cylinder.
4. Retract the stick cylinder rod 60 mm (2.4 inch) from the fully extended position.
View Image
35
5. Raise the boom until the stick to bucket pin is 600.0 mm (23.6 inch) high from ground level. Refer to
Illustration 3.
6. Measure the stick cylinder's length from cylinder pin to cylinder pin.
7. Stop the engine.
8. Leave the machine in this position for five minutes. Measure the stick cylinder's length from cylinder pin to
Table 3

Stick Cylinder
Bucket Cylinder Rod End

2. Fully retract the bucket cylinder.
View Image
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4. Raise the boom until the stick to bucket pin is 600.0 mm ( 23.6 inch) high from ground level. Refer to
Illustration 4.
5. Measure the bucket cylinder's length from cylinder pin to cylinder pin.
6. Stop the engine.
7. Leave the machine in this position for five minutes. Measure the bucket cylinder's length from cylinder pin to
Table 4

Bucket Cylinder
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i03295982
Cylinder Drift - Check - Loaded Bucket

SMCS - 5051-535-FKK; 5117-535-FKK; 5453-535-FKK; 7562-535-D9 ; 7562
used for this test.
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
View Image
1. Position the machine on level ground. Refer to Illustration 1.
2. Load the bucket.
Weight of bucket load

330D and 336D ... 2520 kg (5550 lb)
330D L and 336D L ... 2700 kg (5950 lb)
3. Raise the boom until the top stick pin is the same height as the boom foot pin.
6. Extend the stick cylinder rod 70 mm (2.8 inch) from the fully retracted position.
38
7. Measure each cylinder's length from cylinder pin to cylinder pin.
8. Stop the engine.
9. Leave the machine in this position for three minutes. Measure each cylinder's length from cylinder pin to
Table 2
Cylinder Drift (Loaded Bucket)

Boom Cylinder 12.0 mm (0.47 inch) or less 24.0 mm (0.94 inch) or less
6.0 mm (0.24 inch) or less
Stick Cylinder 12.0 mm (0.47 inch) or less 18.0 mm (0.71 inch) or less 30.0 mm (1.18 inch) or less
Bucket Cylinder
39
i02618446
Cylinder Speed - Check

SMCS - 5456-535-VF ; 5458-535-VF
used for this test.
1. Perform the following steps in order to test the operating speed of the boom cylinders.
View Image
(A) Extension test
(B) Retraction test
a. Place the machine on level ground.
b. The bucket should be empty.
c. Fully retract the bucket cylinder and the stick cylinder.
d. Position the bucket on the ground. With a stopwatch, measure the time that is required to fully extend
the boom cylinders.
e. Position the boom cylinders at full extension. With a stopwatch, measure the time that is required for the
bucket to come in contact with the ground.
f. Refer to the specifications in Table 2 for the operating speed of the boom cylinders.
2. Perform the following steps in order to test the operating speed of the stick cylinder.
View Image
40
(A) Extension test
(B) Retraction test
c. Position the upper surface of the boom parallel to the ground.
d. Fully extend the bucket cylinder.
e. Retract the stick cylinder. With a stopwatch, measure the time that is required to fully extend the stick
cylinder.
f. Extend the stick cylinder. With a stopwatch, measure the time that is required to fully retract the stick
cylinder.
g. Refer to the specifications in Table 2 for the operating speed of the stick cylinder.
3. Perform the following steps in order to test the operating speed of the bucket cylinder.
View Image
(A) Extension test
(B) Retraction test
41
c. Position the upper surface of the boom parallel to the ground.
d. Position the stick so that the stick is perpendicular to the ground.
e. Fully retract the bucket cylinder.
f. With a stopwatch, measure the time that is required to fully extend the bucket cylinder.
g. Position the bucket cylinder at full extension. With a stopwatch, measure the time that is required to
fully retract the bucket cylinder.
h. Refer to the specifications in Table 2 for the operating speed of the bucket cylinder.
Table 1
Cylinder Operating Speed (seconds)

Extension 3.8 ± 0.5 4.5 (1) 5.0 (1)
Boom
Retraction 2.6 ± 0.5 3.3 (1) 3.8 (1)
Extension 3.4 ± 0.5 4.0 (1) 4.5 (1)
Stick
Retraction 2.8 ± 0.5 3.5 (1) 4.0 (1)
Extension 4.4 ± 0.5 5.0 (1) 5.5 (1)
Bucket
Retraction 2.5 ± 0.5 3.2 (1) 3.7 (1)
( 1 ) Maximum
42
i03162328
Relief Valve (Pilot) - Test and Adjust

SMCS - 5072-036
Table 1
Required Tools
8T-0856 Pressure Gauge (6000 kPa (870 psi)) 1
1. Place the machine on level ground.
2. Stop the engine.
3. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic System Pressure -
Release".
View Image
Pilot oil manifold compartment
(1) Locknut
(2) Adjustment screw
(3) Pressure tap
(4) Pilot filter
4. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (3) .
8. Check the pilot relief valve setting at pressure tap (3) .
9. The pilot relief valve setting should be 4100 ± 200 kPa (595 ± 29 psi). If the pilot relief valve setting is not
within the specification, adjust the pilot relief valve.
43
10. In order to adjust the pilot relief valve, loosen locknut (1) .
11. Turn adjustment screw (2) until the pressure gauge reading at pressure tap (3) is 4100 ± 200 kPa (595 ± 29
psi).
Note: Turn adjustment screw (2) clockwise in order to increase the pressure. Turn adjustment screw (2)
counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustments on pressure rise.
12. Tighten locknut (1) to a torque of 49 ± 4.9 N·m (36 ± 4 lb ft).
Note: Normal operation of the engine and pumps are necessary for the pressure adjustment. If the results of the
pressure adjustments are not correct, then the engine and the pump characteristic curve needs to be checked.
44
i03576996
Accumulator (Pilot) - Test and Charge

SMCS - 5077-045-PS ; 5077-081-PS ; 5077-081-PX
Dry nitrogen is the only gas approved for use in the

accumulators. The charging of oxygen gas in an
accumulator will cause an explosion. An explosion
can be eliminated by using nitrogen gas cylinders
with standard CGA (Compressed Gas Association,
Inc.) No. 580 connectors. When nitrogen gas is
ordered, make sure to order the cylinders with CGA
No. 580 connectors.
Do not rely on color codes or other methods of

identification to tell the difference between nitrogen
and oxygen cylinders. In any application, never use
an adapter to connect your nitrogen charging group
to a valve outlet used on both nitrogen, oxygen, or
other gas cylinders. BE SURE YOU USE DRY
NITROGEN (99.8% purity).
NOTICE


and mandates.
Table 1
REQUIRED TOOLS
175-5507 Nitrogen Charging Group 1
(1) Accumulator Charging Gp 1
9U-6740
(2) Adapter 1
334-1071
( 1 ) Required for the 227-8807 Hydraulic Accumulator Gp
( 2 ) Adapter for 9U-6740 Accumulator Charging Gp
45
Preliminary Test
1. Start the engine. Place the hydraulic lockout lever in the UNLOCKED position.
2. Position the implements 1 m (3.3 ft) from the ground.
3. Shut off the engine by turning the start switch to the OFF position. When the engine has stopped, return the
start switch to the ON position.
4. Move the joysticks in order to lower the implements. When the accumulator circuit is functioning properly,
there will be enough stored energy for approximately one minute after a power loss in order to lower the
implements to the ground safely.
5. If the preliminary test fails and the implements are unable to be lowered to the ground safely after a power
loss, proceed to test the accumulator circuit.
Testing the Check Valve (Pilot Manifold)
View Image
Ports of the pilot manifold
(10) Plug
(11) Check valve
View Image
46
(10) Plug
(11) Check valve
If check valve (11) does not close properly during a loss of pilot pressure, the accumulator precharge pressure will
exhaust before being able to provide lowering of the implements.
Note: Make sure that the accumulator has a proper nitrogen gas charge before attempting to test check valve (11) .
An improperly charged accumulator may give indications of a problem with check valve (11) .
1. Stop the engine. Release the pressure from the pilot hydraulic system. Refer to Testing and Adjusting,
"Hydraulic System Pressure - Release".
2. Connect a 6000 kPa (870 psi) pressure gauge to port "PSA2" on the pilot manifold.
3. Start the engine and place the hydraulic lockout lever in the UNLOCKED position.
4. Shut off the engine by turning the start switch to the OFF position. When the engine has stopped, return the
start switch to the ON position.
5. After the power loss, the accumulator will still have pilot system pressure. Use the stopwatch to observe the
pilot pressure. The pilot pressure should stay above 1035 kPa (150 psi) within one minute. This ensures that
enough stored energy is available to lower the implements to the ground.
Note: When the pilot pressure in the accumulator is approximately 860 kPa (125 psi) the pressure will
suddenly drop to zero. This occurs because no oil is left in the accumulator.
6. If the pilot pressure in the accumulator is below 1035 kPa (150 psi) or the pilot supply is exhausted in less
than one minute, check valve (11) is not working properly.
7. Move the joysticks in order to release any pilot hydraulic pressure in the accumulator.
8. Turn off the engine.

9. Clean check valve (11) . Check valve (11) is located behind plug (10) on the pilot manifold. Repeat steps 3
through 5. If the test fails, replace the check valve.
Charge Pressures and Temperatures
47
Gas pressure is variable with temperature. Check the temperature of the air around the accumulator. In order to
check the amount of charge in an accumulator, the accumulator must be at the same temperature as the
surrounding air.
Note: The temperature of the accumulator may change as the accumulator is being charged due to the expansion
or compression of the nitrogen charge. It may be necessary to charge the accumulator in several steps in order to
ensure a correct charge.
Table 2
Charge Pressures and Temperatures

Temperature Pressure
-25°C (-13°F) 1490 kPa (216 psi)
-20°C (-4°F) 1520 kPa (220 psi)
-15°C (5°F) 1550 kPa (225 psi)
-10°C (14°F) 1580 kPa (229 psi)
-5°C (23°F) 1610 kPa (233 psi)
0°C (32°F) 1640 kPa (238 psi)
5°C (41°F) 1670 kPa (242 psi)
10°C (50°F) 1700 kPa (247 psi)
15°C (59°F) 1730 kPa (251 psi)
20°C (68°F) 1760 kPa (255 psi)
25°C (77°F) 1790 kPa (260 psi)
30°C (86°F) 1820 kPa (264 psi)
35°C (95°F) 1850 kPa (268 psi)
40°C (104°F) 1880 kPa (273 psi)
45°C (113°F) 1910 kPa (277 psi)
50°C (122°F) 1940 kPa (281 psi)
Testing the Accumulator (Nitrogen Gas Charge)

Note: Some accumulators do not have a charge pressure port. This type of accumulator cannot be recharged. The
accumulator must be replaced. Replacement accumulators are equipped with a charge pressure port.
48
View Image
Accumulator (Typical Example)
(1) Cap
View Image
175-5507 Nitrogen Charging Group
(2) Pressure gauge
(3) Connection to the nitrogen cylinder
(4) Regulator
(5) Valve
(6) Pressure gauge
(7) Pressure regulating screw
(8) Valve handle
(9) Chuck
View Image
49
(10) Plug
(11) Check valve
View Image
50
(10) Plug
(11) Check valve
2. Make sure that valve (5) is closed.
3. Remove cap (1) from the accumulator.
4. Rotate valve handle (8) on chuck (9) counterclockwise until the valve handle reaches the full out position.
Install chuck (9) on the accumulator.
5. Turn valve handle (8) clockwise until the valve is completely open.
6. Check the pressure reading on pressure gauge (6) . Refer to Table 2 for the correct charging pressure and
temperature relationship for the accumulator.
Note: If the pressure reading is within the specifications of Table 2, continue to test the operation of check
valve (11) . If the pressure reading is too low or too high, refer to Testing and Adjusting, "Charging the
Accumulator" in order to properly charge the accumulator before proceeding to test the operation of check
valve (11) .
Charging the Accumulator
View Image
Accumulator (Typical Example)
(1) Cap
View Image
51
175-5507 Nitrogen Charging Group
(2) Pressure gauge
(3) Connection to the nitrogen cylinder
(4) Regulator
(5) Valve
(6) Pressure gauge
(7) Pressure regulating screw
(8) Valve handle
(9) Chuck
Note: If an accumulator has less than half of the required amount of precharge pressure, the accumulator
should be charged. Oil in the accumulator will give an inaccurate precharge reading.
2. Make sure that valve (5) is closed.
3. Remove cap (1) from the accumulator.
4. Rotate valve handle (8) on chuck (9) counterclockwise until the valve handle reaches the full out position.
Install chuck (9) on the accumulator.
5. Turn valve handle (8) clockwise until the valve is completely open.
6. Check the pressure reading on pressure gauge (6) . Refer to Table 2 for the correct charging pressure and
temperature relationship for the accumulator.
7. If the pressure reading on the gauge is too high, use the following steps in order to purge the nitrogen from
the accumulator.
a. Slowly open valve (5) .
b. Purge the nitrogen pressure until the pressure reading is within the specification.
c. Close valve (5) .
d. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely closed.
e. Remove the test equipment. Replace cap (1) .
8. If the pressure is too low, use the following procedure to charge the accumulator:
52
a. Turn handle (8) on chuck (9) counterclockwise until the valve is completely closed.
b. Connect the 175-5507 Nitrogen Charging Group to the nitrogen cylinder with connection (3) .
c. Connect the other end of the hose to valve (5) .
d. Open the valve on the nitrogen cylinder. Make an adjustment to screw (7) on the regulator assembly
until gauge (2) indicates the proper precharge pressure for the accumulator. Refer to Table 2.
e. Open valve (5) . Loosen chuck (9) slightly. Allow the nitrogen to purge the air from the hose. Tighten
chuck (9) .
f. Turn valve handle (8) on chuck (9) clockwise in order to charge the accumulator.
g. Close valve (5) .
h. The accumulator has the correct charge if the pressure on gauge (6) and the pressure on gauge (2) are
equal and the gauge readings do not change. If there is a decrease in pressure on gauge (6) , open valve
(5) and allow more nitrogen to go into the accumulator.
i. Repeat steps 8.d through 8.g until the following items occur:
The pressure on gauge (6) is equal to the pressure on gauge (2) .
There is no pressure change when valve (5) is closed.
Note: If the accumulator will not maintain a nitrogen charge, the accumulator is damaged. Replace the
accumulator.
ReferenceThe replacement accumulator that comes from the factory is uncharged. Refer to Testing and
Adjusting, "Charging the Accumulator" for the procedure to charge the replacement accumulator.
j. Close valve (5) . Close the valve on the nitrogen cylinder.
k. Turn valve handle (8) on chuck (9) counterclockwise until the valve is completely closed.
l. Open valve (5) . Loosen chuck (9) slightly in order to purge the nitrogen from the lines.
m. Close valve (5) .
n. Remove the test equipment. Replace cap (1) .
53
i03162864
Relief Valve (Main) - Test and Adjust - Heavy Lift

SMCS - 5069-025; 5069-081
Part Number -
S/N - MEY1-UP
Part Number -
S/N - MAG1-UP
Part Number -
S/N - W3K1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - D3P1-UP
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD1-UP
Part Number -
S/N - M4T1-UP
Part Number -
S/N - R2D1-UP
Part Number -
S/N - J2F1-UP
Part Number -
S/N - MWP1-UP
Part Number -
S/N - B6H1-UP
1. Position the machine on level ground and stop the engine.
Release".
View Image
54
Pump compartment
(1) Pressure tap (pressure for drive pump)
(2) Pressure tap (pressure for idler pump)
(3) Pressure tap (power shift pressure)
3. Attach a 60000 kPa (8700 psi) pressure gauge to pressure tap (1) .
View Image
6. Set heavy lift switch (A) to the ON setting. Make sure that the indicator light is on.
8. Raise the boom until the boom cylinder rods are at full extension.
9. Check the pressure setting of the heavy lift at pressure tap (1) .
10. Return the joystick for the boom to the NEUTRAL position.
View Image
55
(4) Main relief valve
(5) Locknut for the heavy lift
(6) Adjustment screw for the heavy lift
(7) Locknut for the main relief valve
(8) Adjustment screw for the main relief valve
Note: When the main relief setting is adjusted the heavy lift setting is not affected. When adjustment screw
(8) is turned counterclockwise in order to decrease the main relief setting the pressure difference between the
main relief setting and heavy lift setting will increase. When adjustment screw (8) is turned clockwise in
order to increase the main relief setting the pressure difference between the main relief setting and heavy lift
setting will decrease.
Note: When the heavy lift setting is increased the main relief setting is also increased. When the heavy lift
setting is decreased the main relief setting is also decreased.
11. The relief valve pressure setting for heavy lift should be 36000 ± 500 kPa (5220 ± 73 psi). If the relief valve
pressure setting for heavy lift is not within the specification, adjust the relief valve pressure setting for heavy
lift.
a. Loosen locknut (5) in order to adjust the relief valve for the heavy lift. Adjust the pressure by turning
adjustment screw for the heavy lift (6) until the pressure gauge reading at pressure tap (1) is 36000 ± 500
kPa (5220 ± 73 psi).
Note: Turning adjustment screw (6) clockwise increases the pressure. Turning adjustment screw (6)
counterclockwise decreases the pressure.
b. Tighten locknut (5) to a torque of 70 ± 10 N·m (50 ± 7 lb ft).
Note: Confirm the heavy lift pressure by raising the boom until the boom cylinder rods are at full
extension.
12. Set heavy lift switch (A) to the OFF setting. The indicator light should not be illuminated.
13. Open the bucket until the bucket cylinder rod is at full retraction.
14. Check the main relief valve pressure setting at pressure tap (1) .
15. Return the joystick for the bucket to the NEUTRAL position.
16. The main relief valve pressure setting should be 35000 ± 500 kPa (5075 ± 73 psi). If the main relief valve
pressure setting is not within the specification, adjust the main relief valve pressure setting.
Note: During adjustment of screw (8) , do not allow screw (6) to move.
17. In order to adjust the main relief valve, loosen locknut (7) and turn adjustment screw (8) until the pressure
gauge reading at pressure tap (1) is 35000 ± 500 kPa (5075 ± 73 psi).
Note: Turning adjustment screw (8) clockwise increases the pressure. Turning adjustment screw (8)
56
18. Tighten locknut (7) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).
Note: If the pilot line for heavy lift prevents proper adjustment of the relief valve settings, the line can be
removed in order to make the adjustments. The machine will need to be off and the hydraulic system pressure will
need to be released in order to remove the pilot line for heavy lift. Make adjustments to the relief valves and
reconnect the pilot line before starting the machine and checking the pressure settings.
Temporary Setting of the Main Relief Valve

Note: In order to adjust line relief valve pressure settings, the main relief valve must be temporarily adjusted to a
higher setting since the line relief valve pressure settings are higher than the main relief valve pressure setting.
View Image
1. Set the heavy lift switch (A) to the ON setting. Make sure that the indicator light is ON.
2. The main relief valve pressure setting should be 36000 ± 500 kPa (5220 ± 73 psi) when the heavy lift mode is
on. If the main relief valve is not within the specification, adjust the main relief valve pressure setting to the
correct pressure specification before performing Step 3. Refer to Testing and Adjusting, "Relief Valve (Main)
- Test and Adjust (Heavy Lift)".
View Image
57
(4) Main relief valve
(5) Locknut for the heavy lift
(6) Adjustment screw for the heavy lift
(7) Locknut for the main relief valve
(8) Adjustment screw for the main relief valve
3. Loosen locknut (5) .
4. Turn screw (6) clockwise for one half turn. Tighten locknut (5) while screw (6) is secured.
5. Perform the desired steps for testing and adjusting the line relief valves.
6. Reset main relief valve pressure setting to the normal operating condition. Refer to Testing and Adjusting,
"Relief Valve (Main) - Test and Adjust (Heavy Lift)".
58
i03317300
Relief Valve (Line) - Test and Adjust

SMCS - 5117-025-L9 ; 5117-081-L9
Part Number -
S/N - MEY1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD1-UP
Part Number -
S/N - R2D1-UP
Part Number -
S/N - MWP1-UP
Part Number -
S/N - B6H1-UP
Table 1
Required Tools
Pressure Gauge (
8T-0856 1
6000 kPa (870 psi))
Note: A temporary setting of the main relief valve pressure is required before any line relief valve pressure setting
is adjusted. Refer to the adjustment procedures in Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
Test
2. Stop the engine.
Release".
View Image
59
Pump compartment
(1) Pressure tap (delivery pressure for drive pump)
(2) Pressure tap (delivery pressure for idler pump)
6. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (3) . This is used to monitor power shift
pressure.
8. Place the machine controls at the following settings: AEC switch OFF. Refer to Testing and Adjusting,
"Engine Performance - Test (Engine Speed)" for engine rpm settings.
View Image
60
Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Home key
(I) OK key
(J) Menu key
10. Start Service Mode and input a fixed power shift pressure. Refer to Table 2 for the correct pressure setting of
each hydraulic circuit.
a. Press menu key (J) .
Note: Make sure that the engine speed dial is set correctly. Refer to Table 2 for the correct setting.
Note: If more than thirty seconds pass between pushing the keys on the keypad, the menu mode will be
cancelled and the previous display will be restored to message display (A) .
b. Press right key (F) in order to highlight "SERVICE" menu option.
c. After the "SERVICE" option is highlighted, press OK key (I) .
View Image
d. After OK key (I) is pressed, the screen in Illustration 3 will be displayed. The password for the service
menu is "FFF2". The keys for direction are used to input the password. Press left key (D) or right key (F)
in order to change the position of the flashing character. Press OK key (I) in order to enter the
61
highlighted character.
e. After entering the last letter of the password, the monitor will continue with the "SERVICE" screen.
f. Repeatedly press down key (E) in order to highlight the "DEVICE TEST" line on the display.
g. After the "DEVICE TEST" line is highlighted, press OK key (I) .
h. Once the "DEVICE TEST" screen is displayed, press down key (E) until "POWER SHIFT PRES"
appears on the display.
i. When "POWER SHIFT PRES" is highlighted, press OK key (I) .
j. The "POWER SHIFT PRES" will now be displayed. Line 4 of the display will now change to a numeric
value. These characters represent the power shift pressure (kPa).
k. Press left key (D) or right key (F) in order to increase or decrease the numeric value that is displayed on
line 4 of the display. Pressing left key (D) decreases the power shift pressure. Pressing right key (F)
increases the power shift pressure.
Note: The value for power shift pressure on the monitor may not always match the pressure reading on
the pressure gauge. Adjust the value on the monitor until the desired power shift pressure is attained on
the pressure gauge that is connected to the pressure tap for power shift pressure. Make sure that the
actual power shift pressure on the pressure gauge is correct for each hydraulic circuit. Refer to Table 2
for the correct power shift pressure.
Note: To prevent a change in power shift pressure during the relief valve adjustment, do not turn the
engine start switch to the OFF position.
Note: Refer to Systems Operation, "Monitoring System" for additional information on Service Mode.
11. The pressure setting for both the head end of the boom cylinders and the rod end of the stick cylinder is
38000 ± 1000 kPa (5500 ± 145 psi). The pressure setting for both the rod end of the boom cylinders and the
head end of the stick cylinder is 37000 ± 1000 kPa (5350 ± 145 psi). The pressure setting for both the head
end and the rod end of the bucket cylinder is 37000 ± 1000 kPa (5350 ± 145 psi).
View Image
Main control valves (front view)
(7) Line relief valve (boom cylinder rod end)
(8) Line relief valve (bucket cylinder head end)
(9) Line relief valve (stick cylinder head end)
(12) Line relief valve (stick cylinder rod end)
62
(20) Line relief valve (bucket cylinder rod end)
The following line relief valves are located on top of the main control valves: boom cylinder rod end, bucket
cylinder head end and stick cylinder head end. The line relief valve for the bucket cylinder rod end is located
under the main control valves and opposite the line relief valve for bucket cylinder head end (8) .
Line relief valves (16) and (17) (boom cylinder head end) are located on the boom lowering control valves.
View Image
Main control valve (bottom view)
(13) Stick drift reduction valve
Line relief valve (12) (stick cylinder head end) is located on stick drift reduction valve (13) .
View Image
Line relief valve (typical example)
(14) Locknut
Note: After relief valve adjustments, cancel Service Mode.
Note: Return the main relief valve pressure to the specified setting after testing and adjusting any line relief valve.
Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust" for the main relief valve pressure setting.
63
Table 2
Line Relief Valve Pressure Settings

Standard Configuration
Cylinder Cylinder Position
Power Shift Pressure Relief Pressure Setting
Retracted
3700 ± 50 kPa (537 ± 7
Bucket 37000 + 2000 - 500 kPa (5360 + 290 - 73 psi)
psi)
Extended Speed Dial 2
3700 ± 50 kPa (537 ± 7

Retracted 37000 + 2000 - 500 kPa (5360 + 290 - 73 psi)
psi)
Speed Dial 2
Boom
2500 ± 50 kPa (363 ± 7
Extended 38000 + 2000 - 500 kPa (5510 + 290 - 73 psi)
psi)
Speed Dial 2
2500± 50 kPa (363 ± 7 psi)

Speed Dial 2
Stick
2800 ± 50 kPa (406 ± 7
Extended 37000 + 2000 - 500 kPa (5360 + 290 - 73 psi)
psi)
Speed Dial 2
Adjustment (Boom Cylinder Head End)

Note: Make sure that the engine speed dial and the power shift pressure for the BOOM RAISE hydraulic circuit is
set correctly. Refer to Table 2 for the correct setting.
Note: If an appropriate location is not available to fully extend the boom cylinders, exchange the functions of the
boom line relief valves. Remove the line relief valve for the boom cylinder head end and the line relief valve for
the boom cylinder rod end from the main control valve. Exchange the location of the line relief valves. Adjust the
pressure of the boom line relief valve that is now attached in the head end. After completion of line relief valve
adjustment, return the respective line relief valves to the original locations.
View Image
64
Boom lowering control valve
(16) Line relief valve (left boom cylinder head end)
(17) Line relief valve (right boom cylinder head end)
(19) Locknut
Note: In order to adjust relief valve (17) on the right boom lowering control valve, relief valve (16) on the
left boom lowering control valve must be temporarily adjusted.
1. Mark the location of adjustment screw (18) on relief valve (16) .
2. Loosen locknut (18) on relief valve (16) on the left boom lowering control valve. Turn adjustment screw (18)
clockwise by one quarter turn. Tighten locknut (19) .
3. Move the joystick for the boom until the boom is at the full BOOM RAISE position (full extension of boom
cylinders). Hold the joystick for the boom in this position.
4. Check the pressure in the boom cylinder head end on the pressure gauge at pressure tap (1) .
6. The pressure gauge reading should be 38000 ± 1000 kPa (5500 ± 145 psi). Refer to Table 2. If the pressure
gauge reading at pressure tap (1) is not within the specification, adjust line relief valve (17) .
7. In order to adjust line relief valve (17) , loosen locknut (19) and turn adjustment screw (18) until the pressure
gauge reading at pressure tap (1) is 38000 ± 1000 kPa (5500 ± 145 psi). Refer to Table 2.
Note: Always make final pressure adjustment on pressure rise.
8. Loosen locknut (19) on relief valve (16) on the left boom lowering control valve. Turn adjustment screw (18)
counterclockwise by one half turn past the marked position. Tighten locknut (19) .
Note: In order to adjust relief valve (16) on the left boom lowering control valve, relief valve (17) on the
right boom lowering control valve must be temporarily adjusted.
9. Mark the location of adjustment screw (18) on relief valve (17) .
10. Turn adjustment screw (18) on relief valve (17) clockwise by one quarter turn. Tighten locknut (19) .
11. Move the joystick for the boom to the full BOOM RAISE position. Hold the joystick for the boom in this
position and check the pressure gauge reading at pressure tap (1) .
gauge reading at pressure tap (1) is not within the specification, adjust line relief valve (16) that is on the left
boom lowering control valve.
14. In order to adjust line relief valve (16) , loosen locknut (19) and turn adjustment screw (18) until the pressure
gauge reading at pressure tap (1) is 38000 ± 1000 kPa (5500 ± 145 psi). Refer to Table 2.
15. Tighten locknut (19) on relief valve (16) .
65
16. Loosen locknut (19) on relief valve (17) on the right boom lowering control valve. Turn adjustment screw
(18) counterclockwise by one quarter turn to the marked position. Tighten locknut (19) .
Adjustment (Boom Cylinder Rod End)

Note: Make sure that the engine speed dial and the power shift pressure for the BOOM DOWN hydraulic circuit
is set correctly. Refer to Table 2 for the correct setting.
Note: In order to adjust the line relief valve pressure setting for the boom cylinder rod end, a temporary
adjustment of the line relief valve for the bucket circuit must be performed. Line relief valve (8) for the
bucket is located on top of the main control valve.
View Image
(14) Locknut
1. Loosen locknut (14) on the line relief valve for the BUCKET OPEN function. Turn adjustment screw (15) by
one half turn in a clockwise direction. Tighten locknut (14) on the line relief valve for the work tool cylinder.
2. Move the joystick for the work tool to the full BUCKET OPEN position (left). Hold the joystick for the work
tool in this position. At the same time, move the joystick for the boom until the boom is at the full BOOM
DOWN position (full retraction of boom cylinders). Hold the joystick for the boom in this position.
3. Check the pressure in the boom cylinder rod end on the pressure gauge at pressure tap (1) .
4. Return the joystick to the NEUTRAL position.
gauge reading at pressure tap (1) is not within the specification, adjust line relief valve (7) that is on the main
control valve.
6. Loosen locknut (14) on the boom line relief valve. Turn adjustment screw (15) until the pressure gauge
reading at pressure tap (1) is 37000 ± 1000 kPa (5366 ± 145 psi). Refer to Table 2.
7. Tighten locknut (14) on the boom line relief valve.
8. After completion of line relief valve adjustment for the boom cylinders, return the line relief valve pressure
setting of the bucket to the specified pressure setting.
66
Adjustment (Stick Cylinder)

Note: Make sure that the engine speed dial and the power shift pressure for the STICK OUT hydraulic circuit is
1. To adjust the line relief valve pressure setting of the stick cylinder rod end, move the joystick for the stick
until the stick is at the full STICK OUT position (full retraction of stick cylinder). Hold the joystick for the
stick in this position.
2. Check the pressure in the stick cylinder rod end on the pressure gauge at pressure tap (2) .
3. Return the joystick for the stick to the NEUTRAL position.
5. In order to adjust line relief valve (12) , loosen locknut (14) on the stick line relief valve. Turn adjustment
screw (15) until the pressure gauge reading at pressure tap (2) is 38000 ± 1000 kPa (5511 ± 145 psi). Refer to
Table 2.
6. Tighten locknut (14) to 20 ± 2 N·m (15 ± 1 lb ft) on line relief valve (12) .
Note: Make sure that the engine speed dial and the power shift pressure for the STICK IN hydraulic circuit is
7. To adjust the line relief valve pressure setting of the stick cylinder head end, move the joystick for the stick
until the stick is at the full STICK IN position (full extension of stick cylinder). Hold the joystick for the stick
in this position.
8. Check the pressure in the stick cylinder head end on the pressure gauge at pressure tap (2) .
Table 2.
Adjustment (Bucket Cylinder)

Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET CLOSE hydraulic
circuit is set correctly. Refer to Table 2 for the correct setting.
1. To adjust the line relief valve pressure setting of the bucket cylinder head end, move the joystick for the
bucket until the bucket is at the full BUCKET CLOSE position (full extension of bucket cylinder). Hold the
joystick for the bucket in this position.
2. Check the pressure in the bucket cylinder head end on the pressure gauge at pressure tap (1) .
5. In order to adjust line relief valve (8) , loosen locknut (14) on the bucket line relief valve. Turn adjustment
67
Table 2.
Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET OPEN hydraulic
7. To adjust the line relief valve pressure setting of the bucket cylinder rod end, move the joystick for the bucket
until the bucket is at the full BUCKET OPEN position (full retraction of bucket cylinder). Hold the joystick
for the bucket in this position.
8. Check the pressure in the bucket cylinder rod end on the pressure gauge at pressure tap (1) .
gauge reading at pressure tap (2) is not within the specification, adjust the line relief valve.
11. In order to adjust the line relief valve, loosen locknut (14) on the bucket line relief valve. Turn adjustment
Table 2.
12. Tighten locknut (14) to 20 ± 2 N·m (15 ± 1 lb ft) on the line relief valve.
13. Reset the main relief valve pressure to the correct setting. Refer to the adjustment procedures in Testing and
Adjusting, "Relief Valve (Main) - Test and Adjust".
68
i03317339
Relief Valve (Line) - Test and Adjust

SMCS - 5117-025-L9 ; 5117-081-L9
Part Number -
S/N - MPL1-UP
Part Number -
S/N - MAG1-UP
Part Number -
S/N - EAH1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - D3P1-UP
Part Number -
S/N - EDX1-UP
Part Number -
S/N - M4T1-UP
Part Number -
S/N - MWP1-UP
Part Number -
S/N - B6H1-UP
Part Number -
S/N - FFK1-UP
Part Number -
S/N - JBT1-UP
Table 1
Required Tools
Pressure Gauge (
8T-0856 1
6000 kPa (870 psi))
Note: A temporary setting of the main relief valve pressure is required before any line relief valve pressure setting
is adjusted. Refer to the adjustment procedures in Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
Test
69
2. Stop the engine.
Release".
View Image
Pump compartment
(1) Pressure tap (drive pump pressure)
(2) Pressure tap (idler pump pressure)
6. Connect a 6000 kPa (870 psi) pressure gauge to pressure tap (3) . This is used to monitor power shift
pressure.
View Image
70
Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Back key
(H) Home key
(I) OK key
(J) Menu key
9. Start Service Mode and input a fixed power shift pressure. Refer to Table 2 for the correct pressure setting of
each hydraulic circuit.
Note: Make sure that the engine speed dial is set correctly. Refer to Table 2 for the correct setting.
71
View Image
j. Place the machine controls at the following settings: engine speed dial 10 and AEC switch OFF. Refer to
Note: Press OK key (I) within 5 seconds after completion of Step 9.j in order to ensure high idle.
k. The "POWER SHIFT PRES" will now be displayed. Line 4 of the display will now change to a numeric
l. Press left key (D) or right key (F) in order to increase or decrease the numeric value that is displayed on
the pressure gauge that is connected to the pressure tap for power shift pressure. Make sure that the
actual power shift pressure on the pressure gauge is correct for each hydraulic circuit. Refer to Table 2
for the correct power shift pressure.
Note: To prevent a change in power shift pressure during the relief valve adjustment, do not exit the
"DEVICE TEST" screen and do not turn the engine start switch to the OFF position.
72
10. The pressure setting for both the head end of the boom cylinders and the rod end of the stick cylinder is
38000 + 2000 - 500 kPa (5510 + 290 - 73 psi). The pressure setting for both the rod end of the boom
cylinders and the head end of the stick cylinder is 37000 + 2000 - 500 kPa (5360 + 290 - 73 psi). The
pressure setting for both the head end and the rod end of the bucket cylinder is 37000 + 2000 - 500 kPa (5360
+ 290 - 73 psi).
View Image
Main control valves (front view)
(7) Line relief valve (boom cylinder rod end)
(8) Line relief valve (bucket cylinder head end)
(9) Line relief valve (stick cylinder head end)
(11) Line relief valve (boom cylinder head end)
(16) Line relief valve (bucket cylinder rod end)
The following line relief valves are located on top of the main control valves: boom cylinder rod end, bucket
cylinder head end and stick cylinder head end. The line relief valve for the bucket cylinder rod end is located
under the main control valves and opposite the line relief valve for bucket cylinder head end (8) .
View Image
(10) Boom drift reduction valve
(11) Line relief valve (boom cylinder head end)
Line relief valve (11) (boom cylinder head end) is located on boom drift reduction valve (10) .
73
View Image
(13) Stick drift reduction valve
Line relief valve (12) (stick cylinder head end) is located on stick drift reduction valve (13) .
View Image
(14) Locknut
Note: After relief valve adjustments, cancel Service Mode.
Note: Return the main relief valve pressure to the specified setting after testing and adjusting any line relief valve.
Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust" for the main relief valve pressure setting.
Table 2
Line Relief Valve Pressure Settings

Standard Configuration
Cylinder Cylinder Position
Power Shift Pressure Relief Pressure Setting
74
Retracted
3700 ± 50 kPa (537 ± 7
Bucket 37000 + 2000 - 500 kPa (5360 + 290 - 73 psi)
Extended psi)
Speed Dial 2
3700 ± 50 kPa (537 ± 7

psi)
Speed Dial 2
Boom
2500 ± 50 kPa (363 ± 7
Extended 38000 + 2000 - 500 kPa (5510 + 290 - 73 psi)
psi)
Speed Dial 2
2500± 50 kPa (363 ± 7 psi)

Speed Dial 2
Stick
2800 ± 50 kPa (406 ± 7
Extended 37000 + 2000 - 500 kPa (5360 + 290 - 73 psi)
psi)
Speed Dial 2
Adjustment (Boom Cylinders)

Note: Make sure that the engine speed dial and the power shift pressure for the BOOM RAISE hydraulic circuit is
1. To adjust the line relief valve pressure setting of the boom cylinder head end, move the joystick for the boom
until the boom is at the full BOOM RAISE position (full extension of boom cylinders). Hold the joystick for
the boom in this position.
2. Check the pressure in the boom cylinder head end on the pressure gauge at pressure tap (1) .
4. The pressure gauge reading should be 38000 + 2000 - 500 kPa (5510 + 290 - 73 psi). Refer to Table 2. If the
pressure gauge reading at pressure tap (1) is not within the specification, adjust line relief valve (11) .
5. In order to adjust line relief valve (11) , loosen locknut (14) on the boom line relief valve. Turn adjustment
screw (15) until the pressure gauge reading at pressure tap (1) is 38000 + 2000 - 500 kPa (5510 + 290 - 73
psi).
Note: In order to adjust the line relief valve pressure setting for the boom cylinder rod end, a temporary
adjustment of the line relief valve for the bucket cylinder rod end must be performed.
Note: Make sure that the engine speed dial and the power shift pressure for the BOOM DOWN hydraulic
7. Loosen locknut (14) on the line relief valve for the BUCKET OPEN function. Turn adjustment screw (15) by
one quarter turn in a clockwise direction. Tighten locknut (14) on the line relief valve for the bucket cylinder.
8. Move the joystick for the bucket until the bucket is at the full BUCKET OPEN position (full retraction of the
bucket cylinder). Hold the joystick for the bucket in this position. At the same time, move the joystick for the
boom until the boom is at the full BOOM DOWN position (full retraction of boom cylinders). Hold the
joystick for the boom in this position.
9. Check the pressure in the boom cylinder rod end on the pressure gauge at pressure tap (1) .
75
11. The pressure gauge reading should be 37000 + 2000 - 500 kPa (5360 + 290 - 73 psi). If the pressure gauge
reading at pressure tap (1) is not within the specification, adjust line relief valve (7) .
12. In order to adjust line relief valve (7) , loosen locknut (14) on the boom line relief valve. Turn adjustment
psi). Refer to Table 2.
13. Tighten locknut (14) to 20 ± 2 N·m (15 ± 1 lb ft)on line relief valve (7) .
14. After completion of line relief valve adjustment for the boom cylinders, return the line relief valve pressure
setting of the bucket to the specified pressure setting.
Note: If an appropriate location is not available to fully extend the boom cylinders, exchange the functions of the
boom line relief valves. Remove the line relief valve for the boom cylinder head end and the line relief valve for
the boom cylinder rod end from the main control valve. Exchange the location of the line relief valves. Adjust the
pressure of the boom line relief valve that is now attached in the head end. After completion of line relief valve
adjustment, return the respective line relief valves to the original locations.
Adjustment (Stick Cylinder)

Note: Make sure that the engine speed dial and the power shift pressure for the STICK OUT hydraulic circuit is
1. To adjust the line relief valve pressure setting of the stick cylinder rod end, move the joystick for the stick
until the stick is at the full STICK OUT position (full retraction of stick cylinder). Hold the joystick for the
stick in this position.
2. Check the pressure in the stick cylinder rod end on the pressure gauge at pressure tap (2) .
reading at pressure tap (2) is not within the specification, adjust line relief valve (12) .
Note: Make sure that the engine speed dial and the power shift pressure for the STICK IN hydraulic circuit is
7. To adjust the line relief valve pressure setting of the stick cylinder head end, move the joystick for the stick
until the stick is at the full STICK IN position (full extension of stick cylinder). Hold the joystick for the stick
in this position.
8. Check the pressure in the stick cylinder head end on the pressure gauge at pressure tap (2) .
76
Adjustment (Bucket Cylinder)

Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET CLOSE hydraulic
1. To adjust the line relief valve pressure setting of the bucket cylinder head end, move the joystick for the
bucket until the bucket is at the full BUCKET CLOSE position (full extension of bucket cylinder). Hold the
joystick for the bucket in this position.
2. Check the pressure in the bucket cylinder head end on the pressure gauge at pressure tap (1) .
5. In order to adjust line relief valve (8) , loosen locknut (14) on the bucket line relief valve. Turn adjustment
Note: Make sure that the engine speed dial and the power shift pressure for the BUCKET OPEN hydraulic
7. To adjust the line relief valve pressure setting of the bucket cylinder rod end, move the joystick for the bucket
until the bucket is at the full BUCKET OPEN position (full retraction of bucket cylinder). Hold the joystick
for the bucket in this position.
8. Check the pressure in the bucket cylinder rod end on the pressure gauge at pressure tap (1) .
reading at pressure tap (2) is not within the specification, adjust the line relief valve.
11. In order to adjust the line relief valve, loosen locknut (14) on the bucket line relief valve. Turn adjustment
12. Tighten locknut (14) to 20 ± 2 N·m (15 ± 1 lb ft) on the line relief valve.
13. Reset the main relief valve pressure to the correct setting. Refer to the adjustment procedures in Testing and
Adjusting, "Relief Valve (Main) - Test and Adjust".
77
i03164187
Swing Motor - Test - Measurement of Case Drain Oil

SMCS - 5058-081-ZW
Table 1
Required Tools
6V-9830 Cap 1
Wrench
1
24 mm (0.94 inch)
Container for Measuring 1
NOTICE


and mandates.
1. Stop the engine.
Release".
3. Attach 311-1362 Vacuum Cap onto the hydraulic tank. Attach an air supply hose onto the assembly. Apply
276 to 414 kPa (40 to 60 psi). This procedure will pull a vacuum on the hydraulic system.
View Image
78
Swing motor compartment
(1) Case drain hose
(2) Tee
4. Disconnect the case drain hose (1) from tee (2). Place the open end of the case drain hose (1) into the
container for measuring.
5. Install 6V-8398 O-Ring Seal and 6V-9830 Cap on tee (2) of the swivel.
View Image
Pilot manifold
(3) Connector
(4) Solenoid valve for swing parking brake
6. Disconnect connector (3) from solenoid valve (4) for the swing parking brake.
7. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
9. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm
settings.
11. Slowly move the swing joystick and make sure that the swing parking brake is activated.
12. Move the swing joystick fully for one minute. Measure the case drain oil.
13. Stop the engine.
14. Connect connector (3) to the solenoid valve (4) for the swing parking brake.
15. Repeat this test procedure three times in order to obtain three measurements. For each test procedure, swing
the upper structure to a different position.
The following values specify the maximum acceptable flow of case drain oil when the swing relief pressure is set
at 31400 ± 1000 kPa (4550 ± 145 psi).
New swing motor ... 30 L/min (7.9 US gpm)

Rebuilt swing motor ... 35 L/min (9.2 US gpm)
79
80
i03266862
Relief Valve (Swing) - Test and Adjust

SMCS - 5454-036
2. Stop the engine.
Release".
View Image
Pump compartment
View Image
Pilot manifold
(4) Solenoid valve for the swing parking brake
(5) Connector
5. Disconnect connector (5) for the solenoid valve for the swing parking brake (4) .
81
7. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm
settings.
8. Move the swing joystick slowly and ensure that the swing parking brake is operating properly.
View Image
Swing motor
(6) Adjustment plug
(7) Locknut
(8) Relief valve (right swing)
(9) Adjustment plug
(10) Locknut
(11) Relief valve (left swing)
9. Slowly move the swing joystick for a full SWING RIGHT operation and check the pressure for relief valve
(8) at pressure tap (2) .
10. Return the swing joystick to the NEUTRAL position.
11. The pressure setting of the swing relief valve is 31400 ± 1000 kPa (4550 ± 145 psi). If the pressure reading at
pressure tap (2) is not within the specification, adjust the swing relief valve.
12. In order to adjust the swing relief valve, loosen locknut (7) . Turn adjustment plug (6) until the pressure
Note: Turning adjustment plug (6) clockwise increases the pressure. Turning adjustment plug (6)
14. Slowly move the swing joystick for a full SWING LEFT operation and check the pressure for relief valve
(11) at pressure tap (2) .
15. Return the swing joystick to the NEUTRAL position.
16. The pressure setting of the swing relief valve is 31400 ± 1000 kPa (4550 ± 145 psi). If the pressure reading at
pressure tap (2) is not within the specification, adjust the swing relief valve.
17. In order to adjust the swing relief valve, loosen locknut (10) . Turn adjustment plug (9) until the pressure
82
Note: Turning adjustment plug (9) clockwise increases the pressure. Turning adjustment plug (9)
19. After completing the test and/or the adjustment procedures for the swing relief valves, stop the engine.
Release".
21. Connect connector (5) to the solenoid valve for swing parking brake (4) .
83
i03296042
Swing Bearing Movement - Measure

SMCS - 7063-082
Use the procedures that follow in order to check the vertical movement and the circular movement of the swing
bearing. Two dial indicators with magnetic bases are required for the procedures.
Procedure To Measure Vertical Movement Of The Swing Bearing

2. Empty the bucket.
3. Position the upper structure parallel with the tracks.
4. Inspect the static torque of the bolts in the swing bearing in order to make sure that the bolts are tightened
properly.
a. Set the torque wrench to a torque value of 800 N·m (590 lb ft).
b. Make a mark on the head of the bolt that is relative to the carbody or the bearing race.
c. Apply the specified torque to the bolt.
d. If the head of the bolt does not move, the torque is within the specification.
e. If the head of the bolt moves, replace the bolt.
View Image
(A) Dial indicator
(B) Dial indicator
(C) Outer race of the swing bearing
(D) Inner race of the swing bearing
(F) Carbody
84
5. Refer to Illustration 1. Position dial indicator (A) between the carbody and the outer race of the swing bearing
(C) . Position dial indicator (B) between the carbody and the outer race of the swing bearing (C) .
Note: Position the dial indicators at the front center of the carbody and at the rear center of the carbody.
View Image
6. Refer to Illustration 2 and move the boom, the stick, and the bucket into the position that is shown.
7. Adjust both dial indicators to "zero".
View Image
8. Refer to Illustration 3 for the correct position of the boom, of the stick, and of the bucket. Lower the boom
until the front of the machine rises from the ground. The angle between the ground and the track should be
approximately 15 degrees.
9. Record the dial indicator readings.
10. Calculate the difference between the values that were recorded in Step 9. If the difference is greater than ±
0.05 mm (± 0.002 inch), additional measurements are necessary. Repeat Step 6 through 9.
11. Remove the dial indicators. Rotate the upper structure three times in a clockwise direction. Rotate the upper
structure three times in a counterclockwise direction.
85
12. Repeat Step 5 through 11 three times. Determine the average value of the three readings. Reference Table 1
for the service limit specifications.
Table 1
Specifications For Vertical Movement

New Service Limit
1.5 mm (0.06 inch) 3.0 mm (0.2 inch)
Procedure To Measure Circular Movement Of The Swing Bearing

2. Empty the bucket.
View Image
(E) 1000 mm (39.4 inch)
3. Position the upper structure parallel to the tracks. Refer to Illustration 4 for the correct position of the boom,
of the stick, and of the bucket.
4. Stop the engine.
View Image
86
(A) Dial indicator
(C) Outer race of swing bearing
(D) Inner race of swing bearing
(F) Magnet
5. Position dial indicator (A) on the outer race of swing bearing (C) . Position a magnet (F) on the inner race of
swing bearing (D) . The value for the measurement will be the average of four readings.
6. By hand, push the side of the bucket in order to rotate the upper structure in a counterclockwise direction as
far as possible. Hold the upper structure in that position while the dial indicator is set to "zero".
7. By hand, push the side of the bucket in order to rotate the upper structure in a clockwise direction as far as
possible. Record the dial indicator reading.
8. Remove the dial indicator. Rotate the upper structure three times in a clockwise direction. Rotate the upper
structure three times in a counterclockwise direction.
9. Perform Step 5 through 8 for each machine position that is shown in Illustration 6. The evaluation of the
movement of the bearing is based on the average value of the four measurements at the four positions that are
shown in Illustration 6.
If the measurements for the circular movement of the swing bearing exceed the specifications that are listed in
Table 2, check the following components for improper function, wear and/or failure:
z swing gear teeth
z pinion gear in the swing drive
z swing drive
z swing motor
z swing brake valve
z swing control valve
Table 2
Specifications for Circular Movement

New Service Limit
4.5 mm (0.18 inch) 13.5 mm (0.53 inch)
View Image
87
88
i03164929
Travel Motor - Test - Measurement of Case Drain Oil

SMCS - 4351-081
Table 1
Required Tools
FT-2542 Blocker Pin 1
6V-9509 Face Seal Plug 1
6V-8398 O-Ring Seal 1
Remote drain hose with an inside diameter of
1
20 mm (0.79 inch)
Wrench
1
29 mm (1.14 inch)
Container for measuring 1
NOTICE


and mandates.
1. Stop the engine.
Release".
View Image
89
Sprocket (left track)
(1) Sprocket
(2) FT-2542 Blocker pin
4. Place blocker pin (2) in sprocket (1) in order to block forward left travel. Refer to Illustration 1.
View Image
Travel motor
(3) 6V-9509 Face seal plug
(4) 6V-8398 O-Ring seal
(5) Case drain hose
(6) Connector
(7) Remote drain hose
(8) Container for measuring
90
5. Disconnect case drain hose (5) from connector (6). Install plug (3) and seal (4) in the open end of case drain
hose (5) .
6. Connect one end of remote drain hose (7) to connector (6). Place the other end of remote drain hose into the
container (8) in order to measure the case drain oil.
7. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
11. Move the left travel lever forward fully for one minute.
12. Measure the amount of case drain oil.
13. Remove blocker pin (2) from sprocket (1) .
14. Move the left travel lever in order to reposition the travel motor.
15. Place blocker pin (2) in sprocket (1) in order to block forward left travel.
16. Repeat Steps 11 through 15 in order to obtain three measurements of case drain oil.
The maximum acceptable flow of case drain oil when the travel crossover relief valves are set at 36800 ± 1500
kPa (5340 ± 220 psi). ... 38 L/min (10.1 US gpm)
91
i03249161
Relief Valve (Crossover) - Test and Adjust

SMCS - 5069-036
Table 1
Required Tools
Pressure Gauge (
8T-0856 1
6000 kPa (870 psi))
Note: A temporary setting of the main relief valve is required before travel crossover relief valves can be tested.
Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
2. Stop the engine.
View Image
Pump compartment
3. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (1) . Use this pressure gauge to monitor the
crossover relief valve pressure setting of the right travel motor.
4. Connect a 60000 kPa (8700 psi) pressure gauge to pressure tap (2) . Use this pressure gauge to monitor the
crossover relief valve pressure setting of the left travel motor.
View Image
92
Sprocket (left track)
(4) Sprocket
(5) FT-2542 Blocker pin
6. Place blocker pin (5) in sprocket (4) in order to block forward left travel. Refer to Illustration 2.
View Image
Monitor
93
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Home key
(I) OK key
(J) Menu key
9. Start Service Mode and input a fixed power shift pressure of 3500 kPa (508 psi).
View Image
94
j. Place the machine controls at the following settings: engine speed dial 3 and AEC switch OFF. Refer to
Note: Press OK key (I) within 5 seconds after completion of Step 9.j.
the pressure gauge that is connected to the pressure tap for power shift pressure. The actual power shift
pressure must be 3500 kPa (508 psi) on the pressure gauge.
Note: To prevent a change in power shift pressure during the relief valve adjustment, do not exit the
View Image
Travel brake valve (left side)
(6) Locknut
(8) Crossover relief valve (forward left travel)
(9) Crossover relief valve (reverse left travel)
(10) Locknut
10. Slowly move the left travel control lever to full FORWARD position and check the pressure gauge reading at
pressure tap (2) . The pressure setting of crossover relief valve (8) should be 37500 ± 1500 kPa (5439 ± 218
psi).
11. Return the left travel control lever to the NEUTRAL position.
12. In order to adjust crossover relief valve (8) , loosen locknut (6) and turn adjustment screw (7) until the
pressure gauge reading at pressure tap (2) is 37500 ± 1500 kPa (5439 ± 218 psi).
95
14. Place blocker pin (5) in sprocket (4) in order to block reverse left travel.
15. Slowly move the left travel lever to full REVERSE position and check the pressure gauge reading at pressure
tap (2) . The pressure setting of crossover relief valve (9) should be 37500 ± 1500 kPa (5439 ± 218 psi).
16. Return the left travel control lever to the NEUTRAL position.
17. In order to adjust crossover relief valve (9) , loosen locknut (10) and turn adjustment screw (11) until the
pressure gauge reading at pressure tap (2) is 37500 ± 1500 kPa (5439 ± 218 psi).
In order to adjust the crossover relief valves on the right travel motor, place blocker pin (5) in the sprocket for
right travel. Use the pressure gauge at pressure tap (1) in order to monitor the crossover relief valve pressure
settings for the right travel motor. Adjust the crossover relief valves on the right travel motor in the same
manner as the adjustment for the left travel motor.
19. After relief valve adjustments, cancel Service Mode.
20. Return the main relief valve pressure to the specified setting after crossover relief valve pressure setting is
attained. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and Adjust".
96
i03188102
Fan Motor Speed (Hydraulic and Radiator Cooling) - Test and Adjust
SMCS - 1386-036; 5061-036
Table 1
Required Tools
Table 2
Cooling fan speeds

Standard and Low Noise 1250 ± 30 rpm
Maximum Speed
High Ambient 1360 ± 30 rpm
Standard and Low Noise 880 ± 30 rpm
Minimum Speed
High Ambient 900 ± 30 rpm
2. Stop the engine.
3. Install 9U-7400 Multitach II Group on the cooling fan.
5. Place the machine controls at the following settings: engine speed dial 10 and AEC switch OFF. Refer to
View Image
97
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) home key
(I) OK key
(J) Menu key
6. Start Service Mode and bring up "CALIBRATIONS" mode. Bring up "FAN SPEED" mode. "FAN SPEED"
mode is within "CALIBRATIONS" mode.
Note: If more than 30 seconds pass between pushing the keys on the keypad, the menu mode will be
View Image
98
d. After Ok key (I) is pressed, the screen in Illustration 2 will be displayed. The password for the service
f. Repeatedly press down key (E) in order to highlight the "CALIBRATIONS" line on the display.
g. After the "CALIBRATIONS" line is highlighted, press OK key (I) .
h. Once the "CALIBRATIONS" screen is displayed, press down key (E) in order to highlight the "FAN
SPEED" line on the display.
i. After the "FAN SPEED" line is highlighted, press OK key (I) .
Note: When you press the "OK" key (I), the monitor will prompt you to set the tachometer. Press OK
key (I) in order to proceed to validate the minimum and maximum cooling fan speeds.
7. A set of blue numbers will appear on monitor display (A). These numbers represent the minimum speed of
the cooling fan in revolutions per minute (rpm). Observe the rpm reading of the tachometer. Refer to Table 2
for the proper rpm setting of the cooling fan at minimum speed.
a. The speed adjustment of the cooling fan is controlled by left key (D) and right key (F). Press left key (D)
in order to decrease the speed setting of the cooling fan and press right key (F) in order to increase the
speed setting of the cooling fan.
b. Once the proper setting of the minimum speed is displayed on the tachometer, press OK key (I) in order
to proceed to validate the maximum cooling fan speed.
8. Observe the rpm reading of the tachometer. Refer to Table 2 for the proper rpm setting of the cooling fan at
maximum speed.
a. For adjustment of the rpm setting of the cooling fan, press left key (D) in order to decrease the speed of
the cooling fan, and press right key (F) in order to increase the speed of the cooling fan.
b. Once the proper setting of the maximum speed is displayed on the tachometer, press OK key (I). The
validation for the fan speed will be complete.
ReferenceFor more information on the validation of the cooling fan speed, refer to Systems Operation,
"Calibration Mode".
99
100
i02668820
Fan Motor Speed (Hydraulic Oil Cooler) - Test and Adjust - Reversible
Fan (if equipped)
SMCS - 5058-036-FM
Table 1
Required Tools
2. Stop the engine.
3. Install a multitach onto the fan. This will be used in order to monitor the fan speed.
5. Place the machine controls at the following settings: AEC switch OFF and engine speed dial "10".
Note: Ensure that the hydraulic activation control lever is in the LOCKED position.
View Image
Keypad on monitor
(1) Home key
(2) Menu key
(3) Cancel key
(4) OK key
7. Press menu key (2) on the keypad.
101
Table 2
MAIN MENU
SERVICE
8. Use the right arrow key to highlight the "SERVICE" menu. Press OK key (4) .
9. Enter the password "FFF2" and press OK key (4).
Table 3
SERVICE
MAINTENANCE
PASSWORD CHANGE
DIAGNOSTIC
ECM INFO
STATUS
CALIBRATIONS
10. Use the up/down arrow keys to select "MAINTENANCE". Press OK key (4).
Table 4
MAINTENANCE
REVERSE FAN
FLTR/FLUID INFO
RECOMMEND INTERVAL
WORK HOUR INFO
11. Use the up/down arrow keys to select "REVERSE FAN". Press OK key (4) .
12. Follow the instructions in the monitor.
13. Ensure that the reverse fan performs the following procedure:
102
{ The fan speed decreases and the engine goes to high idle.
{ After 30 seconds, the fan reverses.
{ After one minute, the engine and reverse fan speed return to max speed. Ensure that the reverse fan
speed is 1500 rpm.
{ Stop the reverse fan by pressing the down arrow key. Ensure that the fan resumes normal rotation and
speed.
103
i03296099
Main Pump (Flow) - Test - Constant Horsepower Flow Control for

Stage 1 Pump
SMCS - 5070-081-FW
Part Number -
S/N - EAH1-724
Part Number -
S/N - MAG1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - MEY1-310
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD1-840
Part Number -
S/N - MWP1-2131
Part Number -
S/N - B6H1-UP
Part Number -
S/N - FFK1-325
This test measures individual pump flow at the pump. Each pump is tested individually for output flow at
specified pressures. The pump that is not being tested is not under load and the pump remains at low pressure
standby.
View Image
The electronic control module is located in the compartment behind the cab.
104
(1) Alarm lamp
(2) Electronic control module
View Image
(3) Monitor
(4) Message display
Note: Before starting main pump flow tests, check display (4) on monitor (3) and alarm lamp (1) on electronic
control module (2) for normal operation. Lamp (1) should be green. If no faults are present, perform the
operational checks. Refer to Testing and Adjusting, "Operational Checks".
Note: If the operational checks indicate that slow speed of an implement is common to the circuits of one pump,
the problem is most likely in the hydraulic system. Then perform the pump flow tests. Refer to Testing and
Adjusting, "Main Pump (Flow) - Test (Constant Horsepower Flow Control)".
Note: If the operational checks indicate that slow speed of an implement is common to both pump circuits, the
problem may be in the engine, the fuel, or the working altitude.
Note: Perform the following procedures before testing the main pump flow.
z Set the pilot pressure to the specifications in Testing and Adjusting, "Relief Valve (Pilot) - Test and Adjust"
for the machine.
z Set the main relief valve to specifications. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and
Adjust" for the machine.
z Calibrate the power shift pressure. Refer to Testing and Adjusting, "Calibration" for the Machine Electronic
Control System.
View Image
105
Flow meter tool layout
(1) Swing motor
(2) Connector at swing motor
(3) 6V-9840 Swivel tee
(4) Makeup line (swing motor)
(6) Negative flow control line (drive pump)
(10) 4C-9910 Portable hydraulic tester (flow meter)
(11) Delivery line (idler pump)
(12) Delivery line (drive pump)
(13) Negative flow control line (idler pump)
(17) 7I-7133 Blocking cover
(23) Drive pump
(24) Idler pump
(29) 1U-8303 Fitting
(30) 5K-9090 O-Ring seal
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(33) 4C-8767 Coupling
(34) 7M-8485 O-Ring seal
106
(35) 4C-6481 Coupler assembly
(36) 4C-6482 Nipple assembly
(37) 4I-6141 Coupling
(38) 8C-9026 Adapter
(40) 6V-9854 Swivel elbow
(42) 1P-3704 Rectangular seal
(46) 8T-4184 Bolt
(47) 8T-4223 Hard washer
(48) 1P-5767 Half flange
(49) 1U-8293 Adapter
View Image
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
107
(9) 8T-0861 Pressure gauge
(11) Delivery line for idler pump
(12) Delivery line from drive pump
(17) 9U-7335 Blocking cover
(21) Engine
(22) Multitach
(23) Drive pump
(24) Idler pump
(40) Elbow
Drive Pump
NOTICE


and mandates.
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
View Image
Pump compartment
108
(12) Delivery line for drive pump
(23) Drive pump
(24) Idler pump
2. Stop the engine.
Release".
5. Install the following tools in accordance with the flow meter tool layout and the circuit diagram. Refer to
Illustration 3 and Illustration 4.
a. Disconnect delivery line (12) from drive pump (23) .
b. Install seal (42) , half flanges (48) and blocking cover (17) to the end of delivery line (12) by using bolts
(46) and washers (47) .
c. Assemble and install seal (42) , adapter (49) , seals (34) , fitting (29) and nipple assembly (36) on drive
pump (23) by using half flanges (48) , bolts (46) and washers (47) .
View Image
Swing motor (top view)
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
d. Disconnect makeup line (4) from connector (2) at swing motor (1) .
e. Assemble and install seals (30) , tee (3) , swivel elbow (40) and coupling (37) to connector (2) at swing
motor (1) .
f. Install seal (30) and makeup line (4) to tee (3) .
109
g. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
h. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at drive pump
(23) and coupling (37) at the swing motor.
i. Connect 4900 kPa (700 psi) pressure gauge (20) to tap (50) for power shift pressure. Connect 49000 kPa
(7100 psi) pressure gauge (9) to tap (16) for drive pump delivery pressure.
j. Install multitach group (22) on engine (21) . This is used to monitor engine speed.
Idler Pump
NOTICE


and mandates.
View Image
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
110
Release".
a. Disconnect delivery line (11) from idler pump (24) .
c. Assemble and install seal (42) , adapter (49) , seals (34) , fitting (29) and nipple assembly (36) on idler
View Image
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
motor (1) .
i. Connect 4900 kPa (700 psi) pressure gauge (20) to pressure tap (50) for power shift pressure. Connect
49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery pressure of the idler pump.
Test
111
To prevent personal injury or equipment damage

from failure of the hydraulic test equipment or
associated circuit components because of blocked
pump flow, make sure that the test equipment valves
are fully open before starting the engine.
To prevent personal injury and/or equipment damage

from failed lines or components while the hydraulic
test equipment is returned to the open flow position,
slowly open the hydraulic test equipment valve while
monitoring the pump flow.
If pump flow does not increase as the valve is opened,

shut the engine off and determine what is preventing
the pump from upstroking.
View Image
Monitor
(A) Display
112
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Home key
(I) OK key
(J) Menu key
3. Start Service Mode and input a fixed power shift pressure of 2850 ± 50 kPa (415 ± 7 psi).
View Image
113
j. Place the machine controls at the following settings: engine speed dial "10" and AEC switch OFF. Refer
to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for engine rpm settings.
Note: To prevent a change in power shift pressure during the main pump flow test, do not exit the
Note: Refer to Systems Operation, "Monitoring System" for the machine for additional information on
Service Mode.
4. In order to perform flow measurements for either one of the pumps, the other pump must not be under load.
View Image
Portable hydraulic tester (flow meter)
(10) Portable hydraulic tester (flow meter)
(22) Multitach
(26) Valve
5. Turn valve (26) on portable hydraulic tester (10) clockwise. Record pump flow at each of the following
pressures in Table 1. Use pressure gauge (9) at pressure tap (16) to monitor the drive pump delivery pressure
or use pressure tap (8) to monitor the delivery pressure of the idler pump.
View Image
114
P-Q characteristic curve
Table 1
Pump Flow Test

Measuring Points
9000 kPa 12000 kPa 16000 kPa 26000 kPa 30000 kPa
(1300 psi) (1750 psi) (2300 psi) (3750 psi) (4350 psi)
Drive
Flow measured liter/min Pump
(US gpm) Idler
Pump
Oil temperature °C (°F)
Engine speed (rpm)
Drive
Flow corrected liter/min Pump
(US gpm) Idler
Pump
273 ± 10
New 259 ± 10 (68 224 ± 10 (59 181 ± 10 (48 168 ± 10 (44
Specification for flow rate (72 ± 2.6)
± 2.6) ± 2.6) ± 2.6) ± 2.6)
liter/min (US gpm)
Service
limit 262 (69) 217 (57) 188 (49) 137 (36) 127 (34)
Note: Specifications for output flow rates are based on an engine speed of 1800 rpm. To attain more accurate test
results, measured flow should be corrected with the following calculation.
115
Table 2
Measured flow x 1800 rpm
Corrected flow =
measured rpm
Note: Specifications for output flow rates are based on a power shift pressure at the pump of 2850 ± 50 kPa (415
± 7 psi). The output flow rate changes approximately 10 L (2.6 US gal) for each 100 kPa (14 psi) of power shift
pressure in the lower range of the constant horsepower control. The output flow rate changes approximately 3
L/min (0.8 US gpm) for each 100 kPa (14 psi) of power shift pressure in the higher range of the constant
horsepower control.
Note: If the output flow rate of the pump is not within the specification, disconnect the negative flow control line
from the pump that is being tested and perform the test again.
Note: Flow measurements must be done only during pressure rise.
116
i03296081
Main Pump (Flow) - Test - Constant Horsepower Flow Control for

Stage 2 Pump
SMCS - 5070-081-FW
Part Number -
S/N - MPL1-UP
Part Number -
S/N - MAG1-UP
Part Number -
S/N - W3K1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - KKT1-UP
Part Number -
S/N - PRF1-UP
Part Number -
S/N - EAH725-UP
Part Number -
S/N - D3P1-UP
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD841-UP
Part Number -
S/N - MWP2132-UP
Part Number -
S/N - M4T1-UP
Part Number -
S/N - R2D1-UP
Part Number -
S/N - J2F1-UP
Part Number -
S/N - FFK326-UP
Part Number -
117
S/N - MEY311-UP
Part Number -
S/N - B6H1-UP
Part Number -
S/N - JBT1-UP
This test measures individual pump flow at the pump. Each pump is tested individually for output flow at
specified pressures. The pump that is not being tested is not under load and the pump remains at low pressure
standby.
View Image
The electronic control module is located in the compartment behind the cab.
(1) Alarm lamp
(2) Electronic control module
View Image
(3) Monitor
(4) Message display
Note: Before starting main pump flow tests, check display (4) on monitor (3) and alarm lamp (1) on electronic
control module (2) for normal operation. Lamp (1) should be green. If no faults are present, perform the
operational checks. Refer to Testing and Adjusting, "Operational Checks".
Note: If the operational checks indicate that slow speed of an implement is common to the circuits of one pump,
the problem is most likely in the hydraulic system. Then perform the pump flow tests. Refer to Testing and
Adjusting, "Main Pump (Flow) - Test (Constant Horsepower Flow Control)".
118
Note: If the operational checks indicate that slow speed of an implement is common to both pump circuits, the
problem may be in the engine, the fuel, or the working altitude.
Note: Perform the following procedures before testing the main pump flow.
z Set the pilot pressure to the specifications in Testing and Adjusting, "Relief Valve (Pilot) - Test and Adjust"
for the machine.
z Set the main relief valve to specifications. Refer to Testing and Adjusting, "Relief Valve (Main) - Test and
Adjust" for the machine.
z Calibrate the power shift pressure. Refer to Testing and Adjusting, "Calibration" for the Machine Electronic
Control System.
View Image
(1) Swing motor
119
(17) 7I-7133 Blocking cover
(23) Drive pump
(24) Idler pump
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(46) 8T-4184 Bolt
(48) 1P-5767 Half flange
View Image
120
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(12) Delivery line from drive pump
(21) Engine
(22) Multitach
(23) Drive pump
(24) Idler pump
(40) Elbow
121
Drive Pump
NOTICE


and mandates.
View Image
Pump compartment
(12) Delivery line for drive pump
(23) Drive pump
(24) Idler pump
2. Stop the engine.
Release".
122
c. Assemble and install seal (42) , adapter (49) , seals (34) , fitting (29) and nipple assembly (36) on drive
View Image
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
motor (1) .
i. Connect 4900 kPa (700 psi) pressure gauge (20) to tap (50) for power shift pressure. Connect 49000 kPa
(7100 psi) pressure gauge (9) to tap (16) for drive pump delivery pressure.
Idler Pump
NOTICE
123

and mandates.
View Image
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
Release".
c. Assemble and install seal (42) , adapter (49) , seals (34) , fitting (29) and nipple assembly (36) on idler
View Image
124
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
motor (1) .
i. Connect 4900 kPa (700 psi) pressure gauge (20) to pressure tap (50) for power shift pressure. Connect
49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery pressure of the idler pump.
Test



125
View Image
Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Home key
(I) OK key
(J) Menu key
126
View Image
127
Service Mode.
4. In order to perform flow measurements for either one of the pumps, the other pump must not be under load.
View Image
(22) Multitach
(26) Valve
5. Turn valve (26) on portable hydraulic tester (10) clockwise. Record pump flow at each of the following
pressures in Table 1. Use pressure gauge (9) at pressure tap (16) to monitor the drive pump delivery pressure
or use pressure tap (8) to monitor the delivery pressure of the idler pump.
View Image
P-Q characteristic curve
128
Table 1
Pump Flow Test

Measuring Points
26000 kPa 30000 kPa

7000 kPa 14000 kPa 18000 kPa
(3750 psi) (4350 psi)
(1025 psi) (2050 psi) (2600 psi)
Drive
Flow measured Pump
liter/min (US gpm) Idler
Pump
Oil temperature °C (°F)
Engine speed (rpm)
Drive
Flow corrected Pump
liter/min (US gpm) Idler
Pump
272 ± 10 235 ± 15 L/min 208 ± 15 L/min

New 175 ± 10 160 ± 10
(72 ± 2.6) (62 ± 4.0 US (55 ± 4.0 US
Specification for flow (46 ± 2.6) (42 ± 2.6)
gpm) gpm)
rate liter/min (US gpm)
Service 252 L/min 155 L/min 140 L/min
210 L/min (55 183 L/min (48
limit (67 US (41 US (37 US
US gpm) US gpm)
gpm) gpm) gpm)
Note: Specifications for output flow rates are based on an engine speed of 1800 rpm. To attain more accurate test
results, measured flow should be corrected with the following calculation.
Table 2
Corrected flow =
measured rpm
Note: Specifications for output flow rates are based on a power shift pressure at the pump of 2700 kPa (390 psi).
The output flow rate changes approximately 10 L (2.6 US gal) for each 100 kPa (14 psi) of power shift pressure in
the lower range of the constant horsepower control. The output flow rate changes approximately 3 L/min (0.8 US
gpm) for each 100 kPa (14 psi) of power shift pressure in the higher range of the constant horsepower control.
Note: If the output flow rate of the pump is not within the specification, disconnect the negative flow control line
from the pump that is being tested and perform the test again.
Note: Flow measurements must be done only during pressure rise.
129
i03018931
Pump Control (Output Flow) - Adjust - Stage 1 Pump

SMCS - 3222-025-FW
Part Number -
S/N - EAH1-724
Part Number -
S/N - MAG1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - MEY1-310
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD1-840
Part Number -
S/N - MWP1-2131
Part Number -
S/N - B6H1-UP
Part Number -
S/N - FFK1-325
Adjust the pump output flow if the flow test results differ greatly from the specifications.
Adjustment of Pump Output Flow (Constant Horsepower Control)
View Image
Main pump compartment
130
(2) Locknut
(4) Locknut
(6) Locknut
(8) Locknut
Adjust the flow of the drive pump for the first stage of the constant horsepower control. The idler pump must be at
no-load condition.
2. Turn adjustment screw (3) in order to adjust the output flow of the pump. Turning adjustment screw (3)
clockwise will increase the output flow of the pump. Turning adjustment screw (3) counterclockwise will
decrease the output flow of the pump. A 1/4 turn of adjustment screw (3) will change the output flow of the
pump at the following pressure.
{ Output flow of the pump will change approximately 29 L/min (7.7 US gpm) if the output flow is
adjusted in the pressure range of 10000 kPa (1450 psi) to 21000 kPa (3050 psi). The pump is operating
in the first stage of the constant horsepower control.
Adjust the flow of the drive pump for the second stage of the constant horsepower control. The idler pump must
be at no-load condition.
{ Output flow of the pump will change approximately 16 L/min (4.2 US gpm) if the output flow is
in the second stage of the constant horsepower control.
3. Tighten locknut (1) to a torque of 16 ± 2.4 N·m (12 ± 1.8 lb ft).
Adjust the idler pump in the same manner as the drive pump. Use locknut (8) and adjustment screw (7) in order to
adjust the first stage of the constant horsepower control. Use locknut (6) and adjustment screw (5) in order to
adjust the second stage of the constant horsepower control.
Adjustment of the Maximum Output Flow of the Pump

Note: Adjustment screws for maximum output flow for both the drive pump and the idler pump are located on the
back side of the pumps.
View Image
131
Top view of main pump compartment
(10) Locknut
(11) Locknut
(13) Idler pump regulator
(14) Drive pump regulator
(15) Pump delivery lines
Adjust the maximum output flow of the drive pump.
2. In order to adjust maximum output flow, turn adjustment screw (12) . Turning adjustment screw (12)
clockwise will decrease the maximum output flow of the pump. Turning adjustment screw (12)
counterclockwise will increase the maximum output flow of the pump. A 1/4 turn of adjustment screw (12)
will change the maximum output flow approximately 7 L/min (1.8 US gpm).
Adjust the maximum output flow of the idler pump in the same manner as the drive pump. Use locknut (10) and
adjustment screw (9) in order to adjust the maximum output flow of the idler pump.
132
i03021084
Pump Control (Output Flow) - Adjust - Stage 2 Pump

SMCS - 3222-025-FW
Part Number -
S/N - MPL1-UP
Part Number -
S/N - MAG1-UP
Part Number -
S/N - W3K1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - KKT1-UP
Part Number -
S/N - PRF1-UP
Part Number -
S/N - EAH725-UP
Part Number -
S/N - D3P1-UP
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD841-UP
Part Number -
S/N - MWP2132-UP
Part Number -
S/N - M4T1-UP
Part Number -
S/N - R2D1-UP
Part Number -
S/N - J2F1-UP
Part Number -
S/N - FFK326-UP
Part Number -
S/N - MEY311-UP
133
Part Number -
S/N - B6H1-UP
Part Number -
S/N - JBT1-UP
Adjust the pump output flow if the flow test results differ greatly from the specifications.
Adjustment of Pump Output Flow (Constant Horsepower Control)
View Image
Main pump compartment
(2) Locknut
(4) Locknut
(6) Locknut
(8) Locknut
Adjust the flow of the drive pump for the first stage of the constant horsepower control. The idler pump must be at
no-load condition.
{ Output flow of the pump will change approximately 24.5 L/min (6.5 US gpm) if the output flow is
in the first stage of the constant horsepower control.
Adjust the flow of the drive pump for the second stage of the constant horsepower control. The idler pump must
be at no-load condition.
134
{ Output flow of the pump will change approximately 13.2 L/min (3.5 US gpm) if the output flow is
in the second stage of the constant horsepower control.
3. Tighten locknut (1) to a torque of 16 ± 2.4 N·m (12 ± 1.8 lb ft).
Adjust the idler pump in the same manner as the drive pump. Use locknut (8) and adjustment screw (7) in order to
adjust the first stage of the constant horsepower control. Use locknut (6) and adjustment screw (5) in order to
adjust the second stage of the constant horsepower control.
Adjustment of the Maximum Output Flow of the Pump

Note: Adjustment screws for maximum output flow for both the drive pump and the idler pump are located on the
back side of the pumps.
View Image
Top view of main pump compartment
(10) Locknut
(11) Locknut
(14) Drive pump regulator
(15) Pump delivery lines
Adjust the maximum output flow of the drive pump.
135
2. In order to adjust maximum output flow, turn adjustment screw (12). Turning adjustment screw (12)
clockwise will decrease the maximum output flow of the pump. Turning adjustment screw (12)
counterclockwise will increase the maximum output flow of the pump. A 1/4 turn of adjustment screw (12)
will change the maximum output flow approximately 5.5 L/min (1.5 US gpm).
Adjust the maximum output flow of the idler pump in the same manner as the drive pump. Use locknut (10) and
adjustment screw (9) in order to adjust the maximum output flow of the idler pump.
136
i03296428
Pump Control (Negative Flow) - Test - Stage 1 Pump

SMCS - 3222-081-FW
Part Number -
S/N - EAH1-724
Part Number -
S/N - MEY1-UP
Part Number -
S/N - MAG1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD1-UP
Part Number -
S/N - MWP1-2131
Part Number -
S/N - B6H1-UP
Part Number -
S/N - FFK1-325
This test measures individual pump flow at the pump while a fixed negative flow control pressure is sent to the
main pump regulator. Each pump is tested individually for an output flow rate at a specified delivery pressure and
a specified negative flow control pressure.
View Image
137
(1) Swing motor
(4) Makeup Line (swing motor)
(23) Drive pump
(24) Idler pump
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
138
(46) 8T-4184 Bolt
(48) 6V-0400 Half flange
View Image
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valves
139
(7) Plug
(8) Pressure tap (delivery pressure for the idler pump)
(9) Pressure gauge
(15) Tees
(16) Pressure tap (drive pump delivery pressure)
(17) Blocking cover
(18) Test line
(20) Pressure gauge
(21) Engine
(22) Multitach group
(23) Drive pump
(24) Idler pump
(40) Elbow
Drive Pump
NOTICE


and mandates.
View Image
140
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
Release".
5. Install the following tools in accordance with the circuit diagram. Refer to Illustration 2.
b. Install seal (42), half flanges (48) and blocking cover (17) to the end of delivery line (12) by using bolts
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on drive
pump (23) by using half flanges (48), bolts (46) and washers (47) .
View Image
(1) Swing motor
(2) Connector
(3) Tee
141
(4) Makeup line
(40) Elbow
e. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing
motor (1) .
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at drive pump
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (16) for drive pump delivery pressure.
i. Install multitach group (22) on engine (21). This is used to monitor engine speed.
View Image
Tool setup
(15) 8T-8902 Tee
(18) 177-7860 Hose assembly
142
(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(28) 3J-1907 O-Ring seal
(41) 6V-3965 Fitting
(43) 6V-4143 Coupler
(44) Test hose
j. Disconnect negative flow control line (6) from drive pump (23). Install seal (25) and plug (7) to the end
of negative flow control line (6) .
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of drive pump (23). Install
cap (27) to tee (15) .
l. Connect one end of test hose (18) to tee (15) .
m. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
n. Connect one end of test hose (44) to tee (15) .
o. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
p. Connect 4900 kPa (700 psi) pressure gauge (20) to the other end of test hose (44) .
Idler Pump
NOTICE


and mandates.
View Image
143
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
Release".
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) to idler
View Image
(1) Swing motor
(2) Connector
(3) Tee
144
(4) Makeup line
(40) Elbow
motor (1) .
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at idler pump
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery pressure of the idler
pump.
View Image
Tool setup
(15) 8T-8902 Tee
145
(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(44) Test hose
j. Disconnect negative flow control line (13) from idler pump (24). Install seal (25) and plug (7) to the end
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of idler pump (24). Install
cap (27) to tee (15) .
Test



146
View Image
Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Back key
(H) Home key
(I) OK key
(J) Menu key
147
View Image
148
Service Mode.
View Image
(22) Multitach
(26) Valve
4. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is 6900 kPa
(1000 psi).
5. Record the negative flow rate in Table 1.
View Image
149
Pressure/Flow characteristic curve
Table 1
Negative Flow Control at

2550 kPa (370 psi)
Drive pump
Oil Temperature °C (°F)
Idler pump
Drive pump
Engine Speed (rpm)
Idler pump
Drive pump
Flow measured liter/min (US gpm)
Idler pump
Drive pump
Flow corrected liter/min (US gpm)
Idler pump
New
170 ± 17 (45 ± 4.5)
Specification for negative flow rate liter/min (US gpm)
Service limit
136 (36)
Note: Specifications for flow rates are based on an engine speed of 1800 rpm. To get more accurate test results,
measured flow should be corrected with the following calculation.
Table 2
Corrected flow =
Measured rpm
Flow measurements must be done in pressure rise.
150
i03296443
Pump Control (Negative Flow) - Test - Stage 2 pump

SMCS - 3222-081-FW
Part Number -
S/N - MPL1-UP
Part Number -
S/N - MAG1-UP
Part Number -
S/N - W3K1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - KKT1-UP
Part Number -
S/N - PRF1-UP
Part Number -
S/N - EAH725-UP
Part Number -
S/N - D3P1-UP
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD841-UP
Part Number -
S/N - MWP2132-UP
Part Number -
S/N - M4T1-UP
Part Number -
S/N - R2D1-UP
Part Number -
S/N - J2F1-UP
Part Number -
S/N - FFK326-UP
Part Number -
S/N - MEY311-UP
151
Part Number -
S/N - B6H1-UP
Part Number -
S/N - JBT1-UP
This test measures individual pump flow at the pump while a fixed negative flow control pressure is sent to the
main pump regulator. Each pump is tested individually for an output flow rate at a specified delivery pressure and
a specified negative flow control pressure.
View Image
(1) Swing motor
(4) Makeup Line (swing motor)
152
(23) Drive pump
(24) Idler pump
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(46) 8T-4184 Bolt
(48) 6V-0400 Half flange
View Image
153
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valves
(7) Plug
(9) Pressure gauge
(15) Tees
(17) Blocking cover
(18) Test line
(20) Pressure gauge
(21) Engine
(23) Drive pump
(24) Idler pump
(40) Elbow
Drive Pump
NOTICE

154
and mandates.
View Image
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
Release".
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) on drive
View Image
155
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
motor (1) .
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at drive pump
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (16) for drive pump delivery pressure.
View Image
Tool setup
156
(15) 8T-8902 Tee
(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(44) Test hose
j. Disconnect negative flow control line (6) from drive pump (23). Install seal (25) and plug (7) to the end
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of drive pump (23). Install
cap (27) to tee (15) .
Idler Pump
NOTICE


and mandates.
157
View Image
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
Release".
c. Assemble and install seal (42), adapter (49), seals (34), fitting (29) and nipple assembly (36) to idler
View Image
158
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
motor (1) .
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at idler pump
h. Connect 49000 kPa (7100 psi) pressure gauge (9) to pressure tap (8) for the delivery pressure of the idler
pump.
View Image
Tool setup
159
(15) 8T-8902 Tee
(23) Drive pump
(24) Idler pump
(27) 6V-9829 Cap
(44) Test hose
j. Disconnect negative flow control line (13) from idler pump (24). Install seal (25) and plug (7) to the end
k. Connect two tees (15) to the elbow at the negative flow signal pressure port of idler pump (24). Install
cap (27) to tee (15) .
Test


160
View Image
Monitor
(A) Display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Back key
(H) Home key
(I) OK key
(J) Menu key
161
View Image
162
Service Mode.
View Image
(22) Multitach
(26) Valve
4. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is 6900 kPa
(1000 psi).
5. Record the negative flow rate in Table 1.
View Image
163
Pressure/Flow characteristic curve
Table 1
Negative Flow Control at

2550 kPa (370 psi)
Drive pump
Oil Temperature °C (°F)
Idler pump
Drive pump
Engine Speed (rpm)
Idler pump
Drive pump
Flow measured liter/min (US gpm)
Idler pump
Drive pump
Flow corrected liter/min (US gpm)
Idler pump
New
180 ± 17 (48 ± 4.5)
Specification for negative flow rate liter/min (US gpm)
Service limit
144 (38)
Note: Specifications for flow rates are based on an engine speed of 1800 rpm. To get more accurate test results,
measured flow should be corrected with the following calculation.
Table 2
Corrected flow =
164
Measured rpm
165
i03024960
Pump Control (Negative Flow) - Adjust - Stage 1 Pump

SMCS - 3222-025-FW
Part Number -
S/N - EAH1-724
Part Number -
S/N - MAG1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - MEY1-310
Part Number -
S/N - EDX1-UP
Part Number -
S/N - NBD1-840
Part Number -
S/N - MWP1-2131
Part Number -
S/N - B6H1-UP
Part Number -
S/N - FFK1-325
View Image
Pump Compartment
(30) Locknut
166
(32) Locknut
Note: Use the same procedure for both pumps. Use locknut (30) and adjustment screw (29) to adjust the drive
pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump.
2. Turn adjustment screw (29) until the negative flow rate is adjusted to the correct specification.
Note: A clockwise adjustment of adjustment screw (29) and adjustment screw (31) decreases the flow rate. A
counterclockwise adjustment increases the flow rate.
Note: A quarter turn of adjustment screw (29) will change the flow rate approximately 21.5 L/min (5.5 US
gpm) which is approximately 100 kPa (15 psi).
3. Tighten locknut (30) to a torque of 16 N·m (12 lb ft).
4. Adjust the idler pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump.
167
i03022523
Pump Control (Negative Flow) - Adjust - Stage 2 Pump

SMCS - 3222-025-FW
Part Number -
S/N - NBD840-UP
Part Number -
S/N - MPL1-UP
Part Number -
S/N - MAG1-UP
Part Number -
S/N - W3K1-UP
Part Number -
S/N - JJM1-UP
Part Number -
S/N - JLP1-UP
Part Number -
S/N - KKT1-UP
Part Number -
S/N - PRF1-UP
Part Number -
S/N - EAH725-UP
Part Number -
S/N - D3P1-UP
Part Number -
S/N - MWP2132-UP
Part Number -
S/N - M4T1-UP
Part Number -
S/N - MEY310-UP
Part Number -
S/N - R2D1-UP
Part Number -
S/N - J2F1-UP
Part Number -
S/N - FFK326-UP
Part Number -
S/N - B6H1-UP
168
Part Number -
S/N - JBT1-UP
View Image
Pump Compartment
(30) Locknut
(32) Locknut
Note: Use the same procedure for both pumps. Use locknut (30) and adjustment screw (29) to adjust the drive
pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump.
2. Turn adjustment screw (29) until the negative flow rate is adjusted to the correct specification.
Note: A clockwise adjustment of adjustment screw (29) and adjustment screw (31) decreases the flow rate. A
counterclockwise adjustment increases the flow rate.
Note: A quarter turn of adjustment screw (29) will change the flow rate approximately 17.9 L/min (4.7 US
gpm) which is approximately 100 kPa (15 psi).
3. Tighten locknut (30) to a torque of 16 N·m (12 lb ft).
4. Adjust the idler pump. Use locknut (32) and adjustment screw (31) to adjust the idler pump.
169
i03182165
Gear Pump (Pilot) - Test

SMCS - 5085-081-GT
View Image
(1) Swing motor
(8) Pilot line (delivery line from the pilot pump)
(9) Connector at pilot pump
(10) Pilot filter
(14) Pilot pump
170
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(48) 8C-8762 Elbow

NOTICE


and mandates.
2. Stop the engine.
Release".
171
View Image
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(6) Plug
(7) Portable hydraulic tester
(8) Pilot line
(9) Connector at pilot pump
(10) Pilot filter
(12) Engine
(14) Pilot pump
(40) Elbow
a. Install multitach group (13) on engine (12) .
172
b. Remove pilot line (8) from connector (9) at pilot pump (14) .
c. Install seal (49) and plug (6) to the end of pilot line (8) .
d. Install seal (49) and elbow (48) to connector (9) at pilot pump (14) .
e. Install seal (34), coupling (47), seal (34) and nipple assembly (36) to elbow (48) .
View Image
Swing motor
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
f. Disconnect makeup line (4) from connector (2) at swing motor (1) .
g. Assemble and install seals (30), tee (3), swivel elbow (40) and coupling (37) to connector (2) at swing
motor (1) .
h. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
i. Connect portable hydraulic tester (7) and test hoses between nipple assembly (36) at the pilot pump and
coupling (37) at the swing motor.
View Image
173
(16) Valve (flow meter)
9. Turn valve (16) on portable hydraulic tester (7) clockwise until the pressure gauge on the portable hydraulic
tester shows a reading of 3900 kPa (565 psi).
10. Record the pilot pump flow at 4100 ± 200 kPa (595 ± 29 psi) in Table 1.
Table 1
Pump Flow Test

Oil Temperature C° (F°)
Engine Speed (rpm)
Flow Measured liter/min (US gpm)
Flow Corrected liter/min (US gpm)
New
40.1 (11)
Specification for Pump Flow liter/min (US gpm)
Service Limit
33 (8.7)
Note: Specifications for pump flow are based on an engine speed of 1800 rpm. To get more accurate test results,
measured flow should be corrected by the following calculation.
Table 2
Corrected flow =
Measured rpm
174
i03296452
Specifications
SMCS - 5050
View Image
Relief valve locations
(A) Main relief valve
(B) Boom cylinder line (head end)
(C) Boom cylinder line (rod end)
(D) Stick cylinder line (head end)
(E) Stick cylinder line (rod end)
(F) Bucket cylinder line (head end)
(G) Bucket cylinder line (rod end)
(H) Swing (right)
(I) Swing (left)
(J) Left travel crossover relief valve for forward travel (upper valve)
(K) Left travel crossover relief valve for reverse travel (lower valve)
(L) Right travel crossover relief valve for forward travel (upper valve)
(M) Right travel crossover relief valve for reverse travel (lower valve)
(N) Pilot relief valve
(O) Main control valve
175
(P) Pilot filter
(Q) Travel motor (right)
(R) Travel motor (left)
(S) Swing motor
Table 1
Specifications
Torque for
Relief Valve New
Service Limit (2) Locknut
Rebuilt (1)
33000 kPa (4790

35000 ± 500 kPa (5075 ± 73 psi) to 69 ± 10 N·m (51 ± 7
psi) 35500 kPa (5150 lb ft)
psi)
(A) Main relief valve
34000 kPa (4930
36000 ± 500 kPa (5220 ± 73
psi) to 50 ± 10 N·m (37 ± 7
psi)
36500 kPa (5300 lb ft)
(Heavy Lift (if equipped))
psi)
36000 kPa (5220

(B) Boom cylinder line (head
38000 + 2000 - 500 kPa (5510 + psi) to
end)
290 - 73 psi) 40000 kPa (5800
psi)
(C) Boom cylinder line (rod end)
35000 kPa (5075
37000 + 2000 - 500 kPa (5360 + psi) to
(D) Stick cylinder line (head 290 - 73 psi) 39000 kPa (5660
end) psi)
20 ± 2 N·m (14 ± 1
lb ft)
36000 kPa (5220
(E) Stick cylinder line (rod end)
38000 + 2000 - 500 kPa (5510 + psi) to
290 - 73 psi) 40000 kPa (5800
psi)
(F) Bucket cylinder line (head
end) 35000 kPa (5075
37000 + 2000 - 500 kPa (5360 + psi) to
(G) Bucket cylinder line (rod 290 - 73 psi) 39000 kPa (5660
end) psi)
(H) Swing relief pressure (right)

29400 kPa (4260
31400 ± 1000 kPa (4550 ± 145 psi) to 117 ± 10 N·m (85 ±
psi) 32400 kPa (4700 7 lb ft)
(I) Swing relief pressure (left) psi)
(J) Left travel crossover relief
valve (forward)
(K) Left travel crossover relief 34500 kPa (5004
valve (reverse) 37500 ± 1500 kPa (5439 ± 218 psi) to 92 ± 8 N·m (68 ± 6
psi) 39000 kPa (5656 lb ft)
(L) Right travel crossover relief psi)
valve (forward)
176
(M) Right travel crossover relief

valve (reverse)
(N) Pilot relief valve 49 ± 5 N·m (36 ± 4

4100 ± 200 kPa (595 ± 29 psi)
lb ft)
( 1 ) A New specification is the performance that can be expected for a new machine. A "Rebuild" specification is the
performance that can be expected after rebuilding the components of a system.
( 2 ) Performance beyond "Service Limit" specifications is an indication of the following problems: improper adjustment, wear,
damage of relief valves and damage of pumps.
Table 2
Required Tools
8T-0470 Thermometer group 1
Table 3
Relief Valves Pressure change With One Turn Of Adjustment Screw
Main valves
14400 kPa (2100 psi)
Line relief valve

11000 kPa (1600 psi)
Swing relief valve

6800 kPa (985 psi)
Travel crossover relief valve

3050 kPa (440 psi)
Pilot relief valve

620 kPa (90 psi)
Note: Pressure values in Table 3 are approximate values. Use a pressure gauge for adjustment.
Note: Normal operations of the engine and pumps are necessary for the pressure adjustments. If the results of the
pressure adjustment are not correct, then the engine and the pump characteristic curve needs to be checked. Slow
output flow from the pump is an indication of air in the hydraulic system. Make sure that no air is present in the
hydraulic system. Refer to Testing and Adjusting, "Main Hydraulic Pump Air - Purge".

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Service Information System Página 1 de 1

General Testing and Adjusting Information

Hydraulic oil pressure can remain in the hydraulic

When possible, the work tool must always be lowered

The swing lock (if equipped) must be engaged before

Always move the machine to a location away from the

Refer to Special Publication, NENG2500,

Dispose of all fluids according to local regulations

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

Hydraulic System Pressure - Release

z Swing hydraulic circuit

Release Of Hydraulic Pressure From A Single Hydraulic Circuit

Personal injury can result from hydraulic oil pressure

Hydraulic oil pressure can remain in the hydraulic

Make sure all of the attachments have been lowered

Care must be taken to ensure that fluids are

Refer to Special Publication, NENG2500,

Dispose of all fluids according to local regulations

1. Position the machine on level ground.

3. Shut off the engine.

5. Place the hydraulic activation control lever in the UNLOCKED position.

7. Place the hydraulic activation control lever in the LOCKED position.

8. Turn the engine start switch to the OFF position.

Release Of Hydraulic Pressure From Multiple Hydraulic Circuits

Personal injury can result from hydraulic oil pressure

Hydraulic oil pressure can remain in the hydraulic

Make sure all of the attachments have been lowered

Refer to Special Publication, NENG2500,

Dispose of all fluids according to local regulations

1. Position the machine on level ground.

3. Shut off the engine.

5. Place the hydraulic activation control lever in the UNLOCKED position.

7. Place the hydraulic activation control lever in the LOCKED position.

8. Start the engine.

11. Shut off the engine.

14. Turn the engine start switch to the OFF position.

Main Hydraulic Pump Air - Purge

Refer to Special Publication, NENG2500,

Dispose of all fluids according to local regulations

Personal injury can result from hydraulic oil pressure

Hydraulic oil pressure can remain in the hydraulic

Make sure all of the work tools have been lowered to

(2) Case drain hose

(3) Pressure tap

1. While the engine is stopped, remove plug (1) .

2. Fill the main pumps with oil.

3. Install plug (1) . Tighten plug (1) securely.

4. Start the engine.

7. Tighten case drain hose (2) to the specified torque.

Overload Warning - Set - If Equipped

Calculation Of The Threshold Pressure For The Overload Warning

(A) Full extension of bucket cylinder

(B) Full retraction of stick cylinder

(C) Position of the pin in the boom foot

(D) Position of the track

(E) Secured position of the bucket

(F) Position of the pin in the stick nose

1. Position the machine. Refer to Illustration 1.

4. Start the engine.