Testing and Adjusting Hydraulic System

320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228 - ...
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Model: 320D EXCAVATOR BZP
Configuration: 320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine
Testing and Adjusting

320D and 323D Excavators Hydraulic System
Media Number -RENR7295-17 Publication Date -01/05/2014 Date Updated -01/05/2014
i02412804
Engine Performance - Test - Engine Speed

SMCS - 1000-081
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228 - ... Page 2 of 4
S/N - JLG1-UP
S/N - JPD1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KLM1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - YSD1-UP
S/N - ZMF1-UP
Table 1
Required Tools
Part Number Description Qty
9U-7400 Multitach Tool Group 1
1. Position the machine on level ground.
2. Stop the engine.
3. Install 9U-7400 Multitach Tool Group on the engine.
4. Start the engine.
5. Increase the hydraulic oil temperature to 55° ± 5°C (131° ± 9°F).
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)
(1)
No load high idle
1980 ± 50 rpm (3) 1780 to 2030 rpm (3)
No load low idle 1000 ± 50 rpm 1000 ± 100 rpm
Maximum speed with load (4) 1760 ± 40 rpm 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.
Copyright 1993 - 2017 Caterpillar Inc. Sun Apr 23 10:31:14 UTC+0700 2017
All Rights Reserved.
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C4.2 and C6.4 Engines for Caterpillar Built Machines
Media Number -KENR6741-23 Publication Date -01/07/2013 Date Updated -30/07/2013
i02928119
Engine Speed - Check

SMCS - 1000
Table 1
Tools Needed
Part Number Part Name Quantity
9U-7400 Multitach Tool Gp 1
OR
(1)
6V-4950 Speed Pickup 1
(1)
Part of 9U-7400 Multitach Tool Gp
Illustration 1 g00286276
9U-7400 Multitach Tool Gp
The 9U-7400 Multitach Tool Gp can measure engine rpm from a magnetic pickup on the flywheel
housing. The 9U-7400 Multitach Tool Gp also has the ability to measure engine rpm from visual
engine parts in rotation.
Note: Refer to Special Instruction, NEHS0605 for the operating instructions of the 9U-7400
Multitach Tool Gp and the instructions for the test procedure.
The 6V-4950 Speed Pickup is another diagnostic tool accessory that can be used with the 9U-7401
Multitach Tool Gp . The 6V-4950 Speed Pickup can be used on single wall fuel injection lines that
are 6 mm (0.25 inch). With these tools, engine speed can be measured quickly with an accuracy of ± 1
rpm.
Note: Refer to Special Instruction, SEHS8029 for the operating instructions of the 6V-4950 Speed
Pickup .
For the maximum engine operating speed (rpm), refer to Operation and Maintenance Manual,
"Emissions Certification Film".
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i02412804
Engine Performance - Test - Engine Speed

SMCS - 1000-081
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KLM1-UP
S/N - KZF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - MZD1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - NZF1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - YSD1-UP
S/N - ZMF1-UP
Table 1
Required Tools
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)
(1)
No load high idle
1980 ± 50 rpm (3) 1780 to 2030 rpm (3)
No load low idle 1000 ± 50 rpm 1000 ± 100 rpm
Maximum speed with load (4) 1760 ± 40 rpm 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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i01371296
Cooling System - Check - Overheating

SMCS - 1350-535
Above normal coolant temperatures can be caused by many conditions. Use the following procedure
to determine the cause of above normal coolant temperatures:
Personal injury can result from escaping fluid under pressure.
If a pressure indication is shown on the indicator, push the release valve

in order to relieve pressure before removing any hose from the radiator.
1. Check the coolant level in the cooling system. If the coolant level is too low, air will get into
the cooling system. Air in the cooling system will cause a reduction in coolant flow and
bubbles in the coolant. Air bubbles will keep coolant away from the engine parts, which will
prevent the transfer of heat to the coolant. Low coolant level is caused by leaks or incorrectly
filling the radiator.
2. Check the mixture of antifreeze and water. The mixture should be approximately 50 percent
water and 50 percent antifreeze with 3 to 6 percent coolant conditioner. If the coolant mixture is
incorrect, drain the system. Put the correct mixture of water, antifreeze and coolant conditioner
in the cooling system.
3. Check for air in the cooling system. Air can enter the cooling system in different ways. The
most common causes of air in the cooling system are not filling the cooling system correctly
and combustion gas leakage into the cooling system. Combustion gas can get into the system
through inside cracks, a damaged cylinder head, or a damaged cylinder head gasket. Air in the
cooling system causes a reduction in coolant flow and bubbles in the coolant. Air bubbles keep
coolant away from the engine parts, which prevents the transfer of heat to the coolant.
4. Check the sending unit. In some conditions, the temperature sensor in the engine sends signals
to a sending unit. The sending unit converts these signals to an electrical impulse which is used
by a mounted gauge. If the sending unit malfunctions, the gauge can show an incorrect reading.
Also if the electric wire breaks or if the electric wire shorts out, the gauge can show an
incorrect reading.
5. Check the radiator.
a. Check the radiator for a restriction to coolant flow. Check the radiator for debris, dirt, or
deposits on the inside of the radiator core. Debris, dirt, or deposits will restrict the flow of
coolant through the radiator.
b. Check for debris or damage between the fins of the radiator core. Debris between the fins
of the radiator core restricts air flow through the radiator core. Refer to Testing and
Adjusting, "Cooling System - Inspect".
6. Check the filler cap. A pressure drop in the radiator can cause the boiling point to be lower.
This can cause the cooling system to boil. Refer to Testing and Adjusting, "Cooling System -
Test".
7. Check the fan and/or the fan shroud. The fan shroud must be the proper size and the fan shroud
must be positioned correctly.
8. Check for loose drive belts.
a. A loose fan drive belt will cause a reduction in the air flow across the radiator. Check the
fan drive belt for proper belt tension. Adjust the tension of the fan drive belt, if necessary.
Refer to the Testing and Adjusting Section, "Belt Tension Chart".
b. A loose water pump drive belt will cause a reduction in coolant flow through the radiator.
Check the water pump drive belt for proper belt tension. Adjust the water pump drive
belt's tension, if necessary. Refer to the Testing and Adjusting Section, "Belt Tension
Chart".
9. Check the cooling system hoses and clamps. Damaged hoses with leaks can normally be seen.
Hoses that have no visual leaks can soften during operation. The soft areas of the hose can
become kinked or crushed during operation. These areas of the hose can cause a restriction in
the coolant flow. Hoses become soft and/or get cracks after a period of time. The inside of a
hose can deteriorate, and the loose particles of the hose can cause a restriction of the coolant
flow.
10. Check for a restriction in the air inlet system. A restriction of the air that is coming into the
engine can cause high cylinder temperatures. High cylinder temperatures require higher than
normal temperatures in the cooling system.
11. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the
engine can cause high cylinder temperatures.
a. Make a visual inspection of the exhaust system.
b. Check for damage to exhaust piping or for a damaged muffler. If no damage is found,
check the exhaust system for a restriction.
12. Check the shunt line. The shunt line must be submerged in the expansion tank. A restriction of
the shunt line from the radiator top tank to the engine water pump inlet will cause a reduction in
water pump efficiency. A reduction in water pump efficiency will result in low coolant flow
and overheating.
13. Check the water temperature regulator. A water temperature regulator that does not open, or a
water temperature regulator that only opens part of the way can cause overheating. Refer to
Testing and Adjusting, "Water Temperature Regulator - Test".
14. Check the water pump. A water pump with a damaged impeller does not pump enough coolant
for correct engine cooling. Remove the water pump and check for damage to the impeller.
15. Check the air flow through the engine compartment. The air flow through the radiator comes
out of the engine compartment. Ensure that the filters, air conditioner, and similar items are not
installed in a way that prevents the free flow of air through the engine compartment.
16. Consider high outside temperatures. When outside temperatures are too high for the rating of
the cooling system, there is not enough of a temperature difference between the outside air and
coolant temperatures.
17. Consider high altitude operation. The cooling capacity of the cooling system goes down as the
engine is operated at higher altitudes. A pressurized cooling system that is large enough to keep
the coolant from boiling must be used.
18. The engine may be running in the lug condition. When the load that is applied to the engine is
too large, the engine will run in the lug condition. When the engine is running in the lug
condition, engine rpm does not increase with an increase of fuel. This lower engine rpm causes
a reduction in air flow through the radiator. This lower engine rpm also causes a reduction in
coolant flow through the system. This combination of less air and less coolant flow during high
input of fuel will cause above normal heating.
19. Timing of the engine which is incorrect may also cause overheating of the engine. Late timing
creates more heat in the engine. Early timing creates less heat in the engine.
Note: If the timing of the engine is incorrect, the exhaust valves may be burned and damage to
the exhaust manifold may occur.
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i01300404
Cooling System - Inspect

SMCS - 1350-040
Cooling systems that are not regularly inspected are the cause for increased engine temperatures.
Make a visual inspection of the cooling system before any tests are performed.

1. Check the coolant level in the cooling system.
2. Look for leaks in the system.
Note: A small amount of coolant leakage across the surface of the water pump seals is normal.
This leakage is required in order to provide lubrication for this type of seal. A hole is provided
in the water pump housing in order to allow this coolant/seal lubricant to drain from the pump
housing. Intermittent leakage of small amounts of coolant from this hole is not an indication of
water pump seal failure.
3. Make sure that air flow through the radiator does not have a restriction. Look for bent core fins
between the folded cores of the radiator. Also, look for debris between the folded cores of the
radiator.
4. Inspect the drive belts for the fan.
5. Check for damage to the fan blades.
6. Look for air or combustion gas in the cooling system.
7. Inspect the filler cap, and check the surface that seals the filler cap. This surface must be clean.
8. Look for large amounts of dirt in the radiator core. Look for large amounts of dirt on the
engine. Remove the dirt from the radiator core and the engine.
9. Fan shrouds that are loose or missing cause poor air flow for cooling.
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i02765190
Cooling System - Test

SMCS - 1350-040; 1350-081
This engine has a pressure type cooling system. A pressure type cooling system has two advantages:
• The pressure type cooling system can operate safely at a higher temperature than the boiling
point of water at a range of atmospheric pressures.
• The pressure type cooling system prevents cavitation in the water pump.
Cavitation is the sudden generation of low pressure bubbles in liquids by mechanical forces. The
generation of an air or steam pocket is more difficult in a pressure type cooling system.
Regular inspections of the cooling system should be made in order to identify problems before
damage can occur. Visually inspect the cooling system before tests are made with the test equipment.
Remember that temperature and pressure work together. When a diagnosis is made of a cooling
system problem, temperature and pressure must be checked. Cooling system pressure will have an
effect on the cooling system temperature. For an example, refer to Illustration 1. This will show the
effect of pressure on the boiling point (steam) of water. This will also show the effect of height above
sea level.
Cooling system pressure at specific altitudes and boiling points of water
Personal injury can result from hot coolant, steam and alkali.
At operating temperature, engine coolant is hot and under pressure.

The radiator and all lines to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only when engine is stopped
and radiator cap is cool enough to touch with your bare hand.
Cooling System Conditioner contains alkali. Avoid contact with skin

and eyes.
The coolant level must be to the correct level in order to check the coolant system. The engine must
be cold and the engine must not be running.
After the engine is cool, loosen the pressure cap in order to relieve the pressure out of the cooling
system. Then remove the pressure cap.
The level of the coolant should not be more than 13 mm (0.5 inch) from the bottom of the filler pipe.
If the cooling system is equipped with a sight glass, the coolant should be to the proper level in the
sight glass.
Test location for water temperature
(1) Plug
Test Tools For The Cooling System

Table 1
Required Tools
Part Number Part Name Qty
4C-6500 Digital Thermometer 1
285-0910 Multi-Tool Gp 1
9S-8140 Pressurizing Pump 1

245-5829 Coolant/Battery Tester Gp 1
Making contact with a running engine can cause burns from hot parts
and can cause injury from rotating parts.
When working on an engine that is running, avoid contact with hot

parts and rotating parts.
4C-6500 Digital Thermometer
The 4C-6500 Digital Thermometer is used in the diagnosis of problems that cause overheating or
overcooling in the engine. This tool can be used to check the temperature in several areas of the
cooling system. The testing procedure is in Tool Operating Manual, NEHS0554.
285-0910 Multi-Tool Gp
The 285-0910 Multi-Tool Gp is used to check the air flow through the radiator core.
9U-7400 Multitach Tool Group
The 9U-7400 Multitach Tool Gp is used to measure the fan speed. Refer to Operating Manual,
NEHS0605, " 9U-7400 Multitach Tool Gp " for the testing procedure.
9S-8140 Pressurizing Pump
The 9S-8140 Pressurizing Pump is used to test the filler caps. This pressurizing pump is also used to
pressure test the cooling system for leaks.
245-5829 Coolant/Battery Tester Gp
Check the coolant frequently in cold weather for the proper glycol concentration. Use the 245-5829
Coolant/Battery Tester Gp in order to ensure adequate freeze protection. The testers are identical
except for the temperature scale. The testers give immediate, accurate readings. The testers can be
used for coolants that contain ethylene or propylene glycol.
Making the Correct Antifreeze Mixtures

Do not add pure antifreeze to the cooling system in order to adjust the concentration of antifreeze.
The pure antifreeze increases the concentration of antifreeze in the cooling system. The increased
concentration increases the concentration of dissolved solids and undissolved chemical inhibitors in
the cooling system.
Add an antifreeze and water mixture in the concentration which provides the desired freeze
protection. Use the following chart in order to determine the correct concentration of antifreeze in
water to use.
Table 2
Antifreeze Concentrations For Freeze Protection
Temperature Concentration
Protection to
30% antifreeze and 70% water
−15 °C (5 °F)
Protection to
−23 °C (−9 °F)
Protection to
−37 °C (−35 °F)
Protection to
−51 °C (−60 °F)
Checking the Filler Cap

Table 3
Required Tools
One cause for a pressure loss in the cooling system can be a faulty seal on the radiator pressure cap.
Typical schematic of filler cap
(1) Sealing surface between the pressure cap and the radiator


and eyes.
To check for the amount of pressure that opens the filler cap, use the following procedure:
1. After the engine cools, carefully loosen the filler cap. Slowly release the pressure from the
cooling system. Then, remove the filler cap.
2. Inspect the pressure cap carefully. Look for damage to the seal. Look for damage to the surface
that seals. Remove any debris on the cap, the seal, or the sealing surface.
Carefully inspect the filler cap. Look for any damage to the seals and to the sealing surface.
Inspect the following components for any foreign substances:
◦ Filler cap
◦ Seal
◦ Surface for seal
Remove any deposits that are found on these items, and remove any material that is found on
these items.
3. Install the pressure cap on the 9S-8140 Pressurizing Pump .
4. Observe the exact pressure that opens the filler cap.
5. Compare the pressure to the pressure rating that is found on the top of the filler cap.
6. If the filler cap is damaged, replace the filler cap.
Testing The Radiator And Cooling System For Leaks

Table 4
Required Tools
320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228... Page 10 of 11

Use the following procedure to test the radiator and the cooling system for leaks.


and eyes.
1. When the engine has cooled, loosen the filler cap to the first stop. Allow the pressure to release
from the cooling system. Then remove the filler cap.
2. Make sure that the coolant covers the top of the radiator core.
3. Put the 9S-8140 Pressurizing Pump onto the radiator.
4. Use the pressurizing pump to increase the pressure to an amount of 20 kPa (3 psi) more than the
operating pressure of the filler cap.
5. Check the radiator for leakage on the outside.
6. Check all connections and hoses of the cooling system for leaks.
The radiator and the cooling system do not have leakage if all of the following conditions exist:
◦ You do NOT observe any leakage after five minutes.
◦ The dial indicator remains constant beyond five minutes.
The inside of the cooling system has leakage only if the following conditions exist:
◦ The reading on the gauge goes down.
◦ You do NOT observe any outside leakage.
Make any repairs, as required.
Cooling System Conditioner
Supplemental cooling system additive contains alkali. To prevent

personal injury, do not drink, avoid contact with the skin and eyes.
NOTICE
All water is corrosive at engine operating temperature. The cooling

system should be protected with a 3% to 6% concentration of cooling
system conditioner at all times.
Caterpillar does not recommend the use of cooling system solutions

that are intended to stop leaks.
Use of these products may result in excessive internal deposits that

could reduce the engine's heat transfer characteristics.
Caterpillar Cooling System Conditioner can be used with an antifreeze or without an antifreeze of
ethylene glycol base in the coolant.
When the conditioner is added to the coolant, the cooling system must be flushed and the cooling
system must be cleaned.
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i05183360
Water Temperature Regulator - Test

SMCS - 1355-081-ON; 1355-081
Introduction
This procedure is intended to give information on testing the water temperature regulator.
Test Procedure

1. Remove the water temperature regulator from the engine.
2. Heat water in a pan until the temperature of the water is equal to the fully open temperature of
the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for the
fully open temperature of the water temperature regulator. Stir the water in the pan. This will
distribute the temperature throughout the pan.
3. Hang the water temperature regulator in the pan of water. The water temperature regulator must
be below the surface of the water. The water temperature regulator must be away from the sides
and the bottom of the pan.
4. Keep the water at the correct temperature for ten minutes.
5. After ten minutes, remove the water temperature regulator. Immediately measure the opening
of the water temperature regulator. Refer to Specifications, "Water Temperature Regulator" for
the minimum opening distance of the water temperature regulator at the fully open temperature.
If the distance is less than the amount listed in the manual, replace the water temperature regulator.
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i05914287
Air in Fuel - Test

SMCS - 1280-081
Table 1
Required Tools
Part
Tool Part Description Qty
Number
A1 334-3221 Nozzle 1
A2 158-6067 Hose 2
A3 124-6275 Hose Clamp 3
A
A4 102-5758 Hose End 2
A5 8D-9448 Boss 1
A6 2P-8278 Sight gauge 1
Typical example
Tooling (A)
NOTICE
Ensure that all adjustments and repairs that are carried out to the fuel
system are performed by authorized personnel that have the correct
training.
Before beginning ANY work on the fuel system, refer to Operation and
Maintenance Manual, "General Hazard Information and High
Pressure Fuel Lines" for safety information.
Refer to Systems Operation, Testing and Adjusting, "Cleanliness of

Fuel System Components" for detailed information on the standards of
cleanliness that must be observed during ALL work on the fuel system.
Note: Ensure that the tools are stored with the caps in place. Store the tools in a clean plastic bag.
1. Ensure that the fuel level in the fuel tank is above the level of the suction pipe in the fuel tank.
2. Inspect the fuel system thoroughly for leaks. If necessary, repair the fuel system.
3. Check all low-pressure fuel lines from the fuel tank for restrictions. Replace any damaged
components.
4. Install new fuel filters. Refer to Operation and Maintenance Manual for the correct procedures.
5. Run the engine. Check if the problem has been resolved. Stop the engine. Refer to Operation
and Maintenance Manual for the correct procedure.
(1) Bolt
(2) Block
6. Install Tooling (A) into block (2) . When possible, install the sight gauge in a straight section of
the fuel line that is at least 304.8 mm (12 inch) long. Do not install the sight gauge near the
following devices that create turbulence:
◦ Elbows
◦ Relief valves
◦ Check valves
Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no
fuel in the sight gauge, prime the fuel system
2P-8278 Tube As (SIGHT GAUGE)
(1) A steady stream of small bubbles with a diameter of approximately 1.60 mm (0.063 inch) is an acceptable
amount of air in the fuel.
(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) are also acceptable if there is 2 second to 3
second intervals between bubbles.
(3) Excessive air bubbles in the fuel are not acceptable.
7. Install a second sight gauge at the inlet to the fuel transfer pump if excessive air is seen in the
sight gauge in the fuel return line. Move the sight gauge from the fuel return line and install the
sight gauge at the inlet to the fuel transfer pump if a second sight gauge is not available.
Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If the engine
starts, check for air in the fuel at varying engine speeds.
If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system
after the fuel transfer pump. Proceed to Step 11.
If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction
side of the fuel system.
8. Remove Tooling (A) and (B) . Reconnect the low-pressure lines.
To avoid personal injury, always wear eye and face protection when
using pressurized air.
NOTICE
To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the
fuel tank.
9. Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid
damage to the fuel tank. Check for leaks in the fuel lines between the fuel tank and the fuel
transfer pump. Repair any leaks that are found.
10. If the source of the air is not found, disconnect the supply line from the fuel tank and connect
an external fuel supply to the inlet of the fuel transfer pump. If this corrects the problem, repair
the fuel tank or the stand pipe in the fuel tank.
11. If the injector sleeve is worn or damaged, combustion gases may be leaking into the fuel
system. Also, if the O-rings on the injector sleeves are worn, missing, or damaged, combustion
gases may leak into the fuel system.
12. Prime the fuel system. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for
the correct procedure. Check that fuel is flowing from the secondary fuel filter base. If there is
no flow of fuel, check the operation of the fuel priming pump. If there is still no flow of fuel,
replace the secondary fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base -
Remove and Install - Secondary Fuel Filter" for the correct procedure.
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i04714928
Engine Oil Pressure - Test

SMCS - 1304-081
Table 1
Tools Needed
1U-5470 Engine Pressure Group 1
An oil pressure gauge that has a defect can indicate low oil pressure.
The 1U-5470 Engine Pressure Group can be used to check engine oil pressure.
1U-5470 Engine Pressure Group
The 1U-5470 Engine Pressure Group has a gauge that measures the oil pressure in the engine. Refer
to Special Instruction, SEHS8907 for more information on using the 1U-5470 Engine Pressure
Group . The information is included in the tool group.
1. Ensure that the engine is filled to the correct oil level.
2. Connect the 1U-5470 Engine Pressure Group to the sender for the engine oil or the sensor for
the engine oil.
3. Operate the engine. Allow the engine to obtain normal operating temperature.
4. Keep the oil temperature constant with the engine at the rated rpm. Read the pressure gauge.
5. Refer to Table 2 in order to determine if the engine oil pressure is in tolerance.
Table 2
Oil Pressure (1)
Oil Pressure at 1500 rpm

195.8- 392.3 kPa (28.4 - 56.9 psi)
(2)
Oil Pressure at Idle
48 kPa (7 psi)
(1)
The oil temperature must be 60° to 70°C (140° to 158°F).
(2)
Idle rpm is 900 ± 20 rpm.
Find the cause of the problem and correct the problem if the results of the test do not fall within the
pressure range in Table 2. Engine failure or a reduction in engine life can be the result if engine
operation is continued with oil pressure outside this range.
Note: A record of engine oil pressure at regular intervals can be used as an indication of possible
problems of the engine. A record of engine oil pressure at regular intervals can also be used as an
indication of possible damage to the engine. The engine should be inspected and the problem should
be corrected if there is a sudden increase or a sudden decrease of 70 kPa (10 psi) in oil pressure.
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Product: EXCAVATOR

320D, 320D2, 321D, 323D, 324D, 325D, 328D, 329D, 330D, 336D, 336D2, 340D and
340D2 Excavators Tool Control System
i04942300
System Identification
SMCS - 5000-546
A tool control system is a hydraulic and electrical system that controls the flow of oil to an attached
work tool on a hydraulic excavator. Refer to Table 1 for the tool control systems that are available.
The system is made up of a machine controller and flow control proportional reducing valves, and
performs flow control against parallel circuits and reduction horsepower control of main pump when
ATT pump is in use.
The machine ECM can hold programs for ten different tool settings. Control parameters for a
maximum of four different spools are included in one type of tool setting. The control parameters
contain not only the oil flow, but also the engine speed and the output limit value for the main pumps.
One or two pump change over for hydraulic hammer and one or two-way flow change over are
performed automatically by control parameters.
The tool control system is set by the factory and stored in the ECM. The default parameters of the
work tool that can be changed are explained for each tool control system.
The machine configuration is determined by the valve control circuit on the machine. The tool
parameter setting is dependent upon the machine configuration setting. The tool control system
should only be changed on the monitor if certain components on the machine are changed first.
The correct "TOOL#" must be selected during the operation of the work tool. Parameters for
the "TOOL#" must be properly programmed. Refer to the specifications of the manufacturer
in order to set the parameters of the "TOOL#".
The component configurations for each of the tool control systems are described in Table 1.
Table 1
Identification for the Tool Control System 320D through 336D
Tool Control Machine Control Tool Relief

Operation
System Application (1) Device Valve
Hydraulic Control - Asia Pacific and Australia (2)
One-Way / One Hydraulic
System 1 SCM Hammer #1 Mechanical
Pump Pedal
Combined Function Hydraulic
System 2 SCM Common Mechanical
Pedal
System 3 Prime One-Way / Two Hydraulic
SCM Hammer #2 Mechanical
Pumps Pedal
System 11 SCM SHEAR Mechanical
Pedal
System 19 SCM SHEAR Mechanical
Pedal (3)
Electric Control - Americas (2)
One-Way / Two Electric
System 3 NACD Hammer Mechanical
Pumps Control (4)
Two-Way / One Electric
System 5 NACD Thumb -
Pump Control (4)
Combined Function NACD Multi-Proc Electric
System 13 Electrical
Control (4)
Combined Function NACD Multi-Proc Electric
Control (4)
Medium Two-Way / Auxiliary Electric
Aux Pump Mechanical
Pressure Pump Control (4)
Electric Control - Europe, Africa, and Middle East (2)
One-Way / One or Electric
System 16 EAME Hammer Mechanical
Two Pumps Control (4)
Combined Function EAME Multi-Proc Electric
Control (4)
Combined Function EAME Multi-Proc Electrical
Control (4)
Medium Two-Way / Auxiliary Electric
Aux Pump Mechanical
Pressure Pump Control (4)
(1)
Monitor Setup Option > "Service" > "Configurations" > "Tool Installation" > "Machine Application"
(2)
Based on original tool system design intent and shipment of machine.
(3)
Medium Pressure has Electric Control
(4)
Joystick with Thumb Wheel, Joystick with 4 Button Switch, Foot Pedal, Foot Switch
System Identifiers
The tool systems can be identified based on the number and type of components on the machine.
Hydraulic Control - Asia Pacific and Australia
System 1
A machine configured with System 1 will offer One-Way flow from One Pump with Hydraulic
Control. System 1 will have the following components:
• One mechanical relief valve located in the swing motor compartment above the boom foot.
• Hydraulic foot pedal in the cab.
Refer to Illustrations 1 and 2 for component descriptions.
Mechanical Tool Relief located above the boom foot
Hydraulic foot pedal located in the cab
System 2
A machine configured with a System 2 will offer Combined Function with Hydraulic Control. System
2 will have the following components:
• Two electronic solenoids and a mechanical relief located above the boom foot.
• Hydraulic controls in the cab.
Two electronic solenoids and a mechanical relief located above the boom foot.
Hydraulic foot pedals located in the cab
System 3 Prime
A machine configured with System 3 Prime will offer One-Way flow from Two Pumps with
Hydraulic Control. System 3 Prime will have the following components:
System 11
A machine configured with a System 11 will offer Combined Function with Hydraulic Control and
Medium Pressure. System 11 will have the following components:
• Medium pressure for tool rotation.
Refer to Illustrations 7, 8, and 9 for component descriptions.
Hydraulic foot pedals located in the cab
Medium pressure valve located in the swing motor compartment (cab side)
System 19
A machine configured with a System 19 will offer Combined Function with Hydraulic Control and
Medium Pressure with Electric Control. System 19 will have the following components:
• Medium pressure with Electric Control stacked on main control valve for tool rotation.
Two Proportional Reducing Valves located in the pump compartment for medium pressure control
Electric Control - Americas
System 3
A machine configured with System 3 offers One-Way flow from One or Two Pumps with Electric
• Two proportional reducing valves to control the attachment control valves located in the main
pump compartment.
• Electric controls in the cab.
Two Proportional Reducing Valves located in the pump compartment
Electric Controls in the cab
(A) Joysticks with Thumb wheel
(B) Electric Foot Pedal
(C) Foot Switch
(D) Joysticks with 4 Button
System 5
A machine configured with System 5 offers Two-Way flow from One Pump. System 5 will have the
following components:
• No dedicated tool relief valve. Only line reliefs on the main control valve.
pump compartment.
(C) Foot Switch
System 13
• Two electronic relief valves located in the swing motor compartment above the boom foot.
• Four proportional reducing valves to control the attachment control valves located in the main
pump compartment.
• (If equipped) Medium pressure for tool rotation.
Refer to Illustrations 18, 19, 20, and 21 for component descriptions.
Two electronic relief valves located above the boom foot
(C) Foot Switch
Four Proportional Reducing Valves located in the pump compartment
(If equipped) Medium pressure valve located in the swing motor compartment (cab side)
System 14
A machine configured with System 14 offers Combined Function with Electric Control. System 14
will have the following components:
• Two electronic solenoid valves with two electronic relief valves located in the swing motor
compartment above the boom foot.
pump compartment.
Two electronic solenoids with two electronic reliefs located above the boom foot
(C) Foot Switch
Medium Pressure Hydraulic System
A machine configured with a Medium Pressure system will have the following components:
• Medium Pressure control valve located in the swing motor compartment.
• Two proportional reducing valves located in the pump compartment.
• Electric control in the cab.
Refer to Illustration 26, 27, and 28 for component descriptions.
Medium pressure valve with proportional reducing valves for control located in the swing motor compartment (cab side)
Electric Control - Europe, Africa, and Middle East
System 16
pump compartment.
(C) Foot Switch
System 17
A machine configured with System 17 offer Combined Function with Electric Control. System 17
• Two electronic solenoid valves with one electronic relief valve located in the swing motor
compartment above the boom foot.
pump compartment.
Two electronic solenoid valves with one electronic relief valve located in the swing motor compartment above the boom
foot.
(C) Foot Switch
System 18
A machine configured with System 18 offer Combined Function with Electric Control. System 18
• Two electronic relief valves located above the boom foot.
pump compartment.
Two electronic relief valves located above the boom foot
(C) Foot Switch
Medium Pressure Hydraulic System
A machine configured with a Medium Pressure system will have the following components:
• Medium Pressure control valve located in the swing motor compartment.
• Two proportional reducing valves located in the pump compartment.
• Electric control in the cab.
Refer to Illustration 40, 41, and 42 for component descriptions.
Medium pressure valve with proportional reducing valves for control located in the swing motor compartment (cab side)
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Product: EXCAVATOR

i05401341
Process for Setting Up the Work Tool

SMCS - 5000-587
The process of setting up a work tool will need to take place when the following occurs:
• Installation of a new tool control system or modification of an existing tool control system
• Major modification to machine hardware
• Machine ECM has been flashed or replaced
When setting the machine up for a work tool system, the electro-hydraulic system must be first
installed on the machine. Then the machine ECM must be programmed to recognize components and
operations for proper operation of the work tool.
The different tool control systems can be identified by referring to Testing and Adjusting, "System
Identification".
All of the following steps require the use of the service mode through the monitor. Refer to Testing
and Adjusting, "Service Mode - Enter" for the Tool Control System for instructions on entering the
service mode.
Setup Overview
1. Each tool control system depends on the physical installation of various valves and hydraulic
lines. Installation of all the hydraulic components and lines must be first accomplished. A list of
all tool control system components is shown in "Tool Control System Components".
2. The machine ECM must be programmed to recognize the installed hydraulic components.
Refer to "Tool Installation Procedure" for the procedure and parameter descriptions.
3. The machine ECM must then be programmed to receive signals from the control inputs that are
installed on the machine. Refer to "Control Installation Procedure" for the procedure and
parameter descriptions.
4. After completion of the Tool Installation and Control Installation, the operation parameters for
the work tool need to be programmed. Refer to Testing and Adjusting, "Work Tool Parameter -
Program" for the Tool Control System.
Note: To view the factory parameter settings for the work tools, refer to Testing and Adjusting,
"Default Value of Work Tool Parameters" for the Tool Control System.
Tool Control System Components

Table 1
Hydraulic Control System Components
System 3 System 11
Name of Tool Control System System 1 System 2
Prime
SCM SCM
SCM SCM
Work Tool Application Hammer #1 Hammer #2
Common SHEAR
Combination of ATT valves

Standard f2 valve 1 1 1 1
Additional ATT F2 valve - 1 1 1
Additional ATT F3 valve - - - -
Additional ATT F4 valve - - - 1
Input Components
Hammer pressure switch 1 1 1 1
Medium pressure switch - - 1
Auxiliary pressure switch - - - -
Boom UP pressure switch - 1 1 -
Output Components
Flow limit proportional reducing
1 1 1 1
valve
Two pump combined flow change
- - 2 2
solenoid (SOL1 and SOL2)
Hammer Return Solenoid (EC1,
- - 3 3
EC2, and SOL3)
Table 2
Electric Control System Components
System 3 System 5 System 13 System 14 Medium
Tool Control System
Pressure
NACD Auxiliary
Work Tool Application NACD NACD NACD
Multi-Proc Pump -
Hammer Thumb Complete
Electrical
Standard f2 valve 1 1 1 1 -
Separate type medium
- - - - 1
pressure valve
Input Components
Modulation switch (Left
1 (1) 1 (1) 1 (1) 1 (1) 1 (1)
Joystick)
Modulation switch
1 (1) 1 (1) 1 (1) 1 (1) -
(Right Joystick)
Switch (Left Joystick) 1 (1) 1 (1) 1 (1) 1 (1) -
Switch (Right Joystick)
1 (1) 1 (1) 1 (1) 1 (1) -
Left Foot Pedal 1 (1) 1 (1) 1 (1) 1 (1) 1 (1)

Right Foot Pedal 1 (1) 1 (1) 1 (1) 1 (1) 1 (1)
Foot Switch 1 (1) 1 (1) 1 (1) 1 (1) -
Tool load pressure
- - 1 1 -
sensor
Output Components
Flow limit proportional
1 - 1 1 -
reducing valve
Hammer return solenoid
- - - 1 (2) -
(E-CV)
ATT valve #1 extend
side proportional 1 1 1 1 -
reducing valve
ATT valve #1 retract
side proportional - 1 1 1 -
reducing valve
ATT valve #2 extend

side proportional 1 1 1 1 -
reducing valve
side proportional - 1 1 1 -
reducing valve
ATT valve #3 extend
side proportional - - - - 1
reducing valve
side proportional - - - - 1
reducing valve
Solenoid variable relief
- - 1 1 -
valve 1 (E-RV1)
Solenoid variable relief
- - 1 1 -
valve 2 (E-RV2)
Variable relief check #2
- - - 1 (2) -
solenoid (E-CV2)
(1)
If equipped
(2)
System 14 only
Table 3
Electric Control System Components
Medium Pressure
Tool Control System System 16 System 17 System 18
EAME
EAME EAME Auxiliary Pump -
Work Tool Application Multi-Proc
Hammer Complete Electrical

Standard f2 valve 1 1 1 -
Separate type medium
- - - 1
pressure valve
Input Components
Modulation switch (Left
1 (1) 1 (1) 1 (1) 1 (1)
Joystick)
Modulation switch (Right
1 (1) 1 (1) 1 (1) -
Joystick)
Switch (Left Joystick) 1 (1) 1 (1) 1 (1) -

Switch (Right Joystick) 1 (1) 1 (1) 1 (1) -
Left Foot Pedal 1 (1) 1 (1) 1 (1) 1 (1)
Right Foot Pedal 1 (1) 1 (1) 1 (1) 1 (1)
Foot Switch 1 (1) 1 (1) 1 (1) -
Tool load pressure sensor - - - -
Output Components
Flow limit proportional
1 1 1 -
reducing valve
Hammer return solenoid (E-
- 1 (2) - -
CV)
ATT valve #1 extend side
1 1 1 -
proportional reducing valve
ATT valve #1 retract side
- 1 1 -
1 1 1 -
- 1 1 -
- - - 1
- - - 1
Solenoid variable relief valve
- 1 1 -
1 (E-RV1)
Solenoid variable relief valve
- 1 1 -
2 (E-RV2)
Variable relief check #2
- 1 (3) - -
solenoid (E-CV2)
(1)
If equipped
(2)
System 17 only
(3)
System 17 only - if equipped
Tool Installation Procedure
Monitor Procedure
The following procedure will allow the user to program the electro hydraulic components into the
machine ECM using the monitor.
1. Enter the "Service Mode" using password "FFF2". Refer to Testing and Adjusting, "Service
Mode - Enter" for the Tool Control System for instructions on entering the service mode.
(A) Up key
(B) Right key
(C) Home key
(D) Main menu
(E) Left key
(F) Down key
(G) Cancel key
(H) OK key
2. Select "CONFIGURATION" from the "Service" menu. Press the OK key.
3. Select "TOOL INSTALLATION" from the "CONFIGURATION" menu. Press the OK key.
4. Use the arrow keys to highlight the parameter. Press the OK key to change the default value.
5. Use the arrow keys to change the value or designation of the parameter. Press the OK key to
enter the change.
Note: Setting the "MACHINE APPLICATION" will automatically load all the factory
parameter setting options for the tool control system that are listed below the "MACHINE
APPLICATION" option.
ReferenceTo view the factory parameter settings for the tool control systems, refer to "Tool
Installation Parameters".
ReferenceRefer to"Tool Installation Parameter Descriptions" for descriptions of each of the Tool
Installation parameters that are available for the tool control system.
Cat Electronic Technician Procedure

The following procedure will allow the user to program the electro hydraulic components into the
machine ECM using Cat Electronic Technician.
1. Connect the Cat Electronic Technician to the diagnostic connector.
2. Start Cat Electronic Technician.
3. Select the ECM for "Machine Control".
4. Select "Configuration" from the "Service"menu.
5. Expand the list for "Auxiliary Hydraulic Attachment Configurations". Highlight "Machine
Application Configuration" and click on the "Change" button on the lower left corner.
6. Select the appropriate "Machine Application" for the machine. Press OK to enter the change.
Note: Setting the "Machine Application" will automatically load all the factory parameter
setting options for the tool control system that are listed below the "Machine Application"
option.
ReferenceTo view the factory parameter settings for the tool control systems, refer to "Tool
Installation Parameters".
ReferenceRefer to"Tool Installation Parameter Descriptions" for descriptions of each of the Tool
Tool Installation Parameters

Table 4
Hydraulic Control Systems - Tool Installation Parameter Settings
Parameter System 3 Prime

System 1 System 2 System 11
Description
1 "Machine "SCM Hammer "SCM "SCM Hammer
"SCM Shear"
Application" #1" Common" #2"
2 Flow Limit
Installed Installed Installed Installed
Valve
3 "Attachment F2 - One Way or F2 - One Way or
F2 - One Way F2 - One Way
Valve #1" Two Way Two Way
4 "Attachment F2 - One Way or F2 - One Way or
Not Installed F2 - One Way
Valve #2" Two Way Two Way
5 "Attachment
Not Installed Not Installed Not Installed F4 - Two Way
Valve #3"
Attachment Attachment Attachment Attachment
6 "Attachment
Pump Valve - Pump Valve - Pump Valve - Pump Valve -
Valve #4"
Two Way Two Way Two Way Two Way
"Attachment
7
Valve #1 Type" Hydraulic Hydraulic Hydraulic Hydraulic
"Attachment
8
Valve #2 Type " Hydraulic Hydraulic Hydraulic Hydraulic
"Attachment
9
"Attachment
10
Valve #2 Valve #2 Valve #2

11 "Combiner
Not Installed Combined with Combined with Combined with
Valve"
12 "Flow
Not Installed Installed Not Installed Installed
Combine"
13 "Hammer
Not Installed Installed Not Installed Installed
Return"
14 "Variable Relief
Not Installed Not Installed Not Installed Not Installed
Valve #1"
15 "Variable Relief
Valve #2"
"Tool Load
16
Pressure Not Installed Not Installed Not Installed Not Installed
Sensor"
Table 5
Electric Control Systems - Tool Installation Parameter Settings
Parameter System 5 Medium
Description Pressure
"NACD "NACD "Auxiliary
1 "Machine "NACD NACD
Thumbl" Multi-Proc" Pump -
Application" Hammer" Compltete
Electrical"
2 Flow Limit Not Not Installed
Installed Installed Installed
Valve Installed
F2 - One F2 - One
3 "Attachment F2 - One F2 - Two Not Installed
Way or Two Way or Two
Valve #1" Way Way
Way Way
F2 - One F2 - One
4 "Attachment F2 - One Not Not Installed
Way or Two Way or Two
Valve #2" Way Installed
Way Way
Attachment
5 "Attachment Not Installed Not Not Installed Not Installed
Pump Valve -
Valve #3" Installed
Two Way
6 "Attachment Not Installed Not Not Installed Not Installed Not Installed
Valve #4" Installed
"Attachment
7 Electrical
Valve #1 Electrical Electrical Electrical Hydraulic
Type"
"Attachment
8 Hydraulic
Valve #2 Type Electrical Electrical Electrical Hydraulic
"
"Attachment
9 Hydraulic
Valve #3 Hydraulic Hydraulic Hydraulic Electrical
Type"
"Attachment
10 Hydraulic
Valve #4 Hydraulic Hydraulic Hydraulic Hydraulic
Type"
"Attachment
11 Combined Not Combined Combined Not Installed
Valve #1
with Valve Installed with Valve with Valve
Combine"
#1 #1 #1
12 "Flow Not Installed Not Not Installed Not Installed Not Installed
Combine" Installed
13 "Hammer Not Installed Not Not Installed
Installed Installed
Return" Installed
Installed on Installed on
"Variable
14 Not Installed Not Valve #1 Valve #1 Not Installed
Relief Valve
Installed Extend port Extend port
#1"
"Variable
Relief Valve
Installed Retract port Retract port
#2"
"Tool Load
Pressure
Installed Extend Port Extend Port
Sensor"
Table 6
Electric Control Systems - Tool Installation Parameter Settings
Parameter Medium
Description Pressure
"EAME
1 "Machine "EAME "EAME Multi- "EAME
Auxiliary Pump"
Application" Hammer" Proc" Complete"
2 "Flow Limit
Installed Installed Installed Not Installed
Valve"
3 "Attachment F2 - One Way F2 - One Way F2 - One Way
Not Installed
Valve #1" or Two Way or Two Way
4 "Attachment F2 - One Way F2 - One Way F2 - One Way
Not Installed
Valve #2" or Two Way or Two Way
Attachment
5 "Attachment
Not Installed Not Installed Not Installed Pump Valve -
Valve #3"
Two Way
6 "Attachment
Valve #4"
"Attachment
7
Valve #1 Type" Electrical Electrical Electrical Hydraulic
"Attachment
8
Valve #2 Type " Electrical Electrical Electrical Hydraulic
"Attachment
9
Valve #3 Type" Hydraulic Hydraulic Hydraulic Electrical
"Attachment
10
"Attachment Valve #2 Valve #2 Valve #2

11
Valve #1 Combined with Combined with Combined with Not Installed
Combine" Valve #1 Valve #1 Valve #1
12 "Flow Combine"
13 "Hammer
Not Installed Installed Installed Not Installed
Return"
14 "Variable Relief
Not Installed Valve #1 Valve #1 Not Installed
Valve #1"
Extend Port Extend Port
15 "Variable Relief
Not Installed Valve #1 Valve #1 Not Installed
Valve #2"
Retract Port Retract Port
"Tool Load
16
Pressure Sensor" Not Installed Not Installed Not Installed Not Installed
Tool Installation Parameter Descriptions

Table 7
Tool Installation Parameter Descriptions
# Monitor
Cat ET Name Description Purpose / Explanation
Name
If the desired item were once selected
among the previously defined names
Machine "Machine
1 General tool of tool control system, the settings
Application Application"
setting here after are automatically updated to
Configuration
the defined settings. Also, setting here
after could be changed individually.
Installation of Installation status of the flow limit

2 Flow Limit Flow Limit
Flow Limit valve to control pump flow to the
Valve Valve
Valve work tool.
Operation setting of ATT valve #1 and
driving pump is set. For stackable
valve (F2):
When 1WAY alone is used, select
"ONE WAY"
"TWO WAY"
When switching 1WAY/2WAY,
Attachment Installation select "ONE or TWO WAY".
3 "Attachment
Valve #1 setting of ATT Set drive pump (Pump#1) and idler
Valve #1"
Configuration valve #1 l pump (Pump#2), respectively. When
ATT pump is used.
Select "Attachment Pump Valve"
"ONE WAY"
"TWO WAY"
When switching 1WAY/2WAY,
select "ONE or TWO WAY".
Attachment Installation Operation setting of ATT valve #2 and
4 "Attachment
Valve #2 setting of ATT driving pump is set. Setting procedure
Valve #2"
Configuration valve #2 is similar as ATT #1.
5 "Attachment
Valve #3"
6 "Attachment
Valve #4"
Set control method of ATT valve #1.
Hydraulic pilot method
Attachment "HYDRAULIC"
"Attachment Control method
7 Valve #1 Control Electric pilot method
Valve #1 of ATT valve
Type "ELECTRICAL"
Type" #1
Configuration Hydraulic pilot + Electric control
method: Select "HYDRAULIC WITH
ELECTRICAL ASSIST"
Attachment
"Attachment Control method Set control method of ATT valve #2.
8 Valve #2 Control
Valve #2 of ATT valve Setting procedure is similar as ATT
Type
Type " #2 #1.
Configuration
Attachment
9 Valve #3 Control
Valve #3 of ATT valve Setting procedure is similar as ATT #1
Type
Type" #3
Configuration
Attachment
10 Valve #4 Control
Valve #4 of ATT valve Setting procedure is similar as ATT
Type
Type" #4 #1.
Configuration
Set necessity of combined pump flow
Installation piping of ATT valve #1 and ATT
Attachment setting of valve #2. "INSTALLED" is selected
11 "Combiner
Valve Combiner 2pump when combined flow piping is
Valve"
Configuration combined flow provided. "NOT INSTALLED" is
piping selected when restricted in one pump
flow operation.
Set necessity of combined pump flow
Installation solenoid valve of ATT valve #1 and
setting of ATT valve #2. "INSTALLED" is
Aux Flow
12 Auxiliary Valve 2pump selected when combined flow solenoid
Combiner
Flow Combine combined flow valve is provided. "NOT
Valve
change solenoid INSTALLED" is selected when
restricted in one pump flow operation.
Installation
Installation status of the solenoid to
13 Hammer Return Hammer setting of the
change one way/two way flow is set.
Configuration Return hammer return
solenoid
Installation
Setting of location of ATT valve to
Variable Relief "Variable setting of
14 install solenoid variable relief valve
Valve #1 Relief Valve solenoid
#1, and the installing line. Ext: Extend
Configuration #1" variable relief
side, Ret: Retract side.
valve #1
Installation
Setting of location of ATT valve to
Variable Relief "Variable setting of
15 install solenoid variable relief valve
Valve #2 Relief Valve solenoid
#2, and the installing line. Ext: Extend
Configuration #2" variable relief
side, Ret: Retract side.
valve #2
Tool Load Sense Installation Establish a line where ATT valve is
"Tool Load
16 Pressure Sensor setting of tool located to install tool load pressure
Pressure
Installation load pressure sensor for enhancement of
Sensor"
Status sensor synchronous operation.
Control Installation Procedure
Monitor Procedure
The following procedure will allow the user to program the electric or hydraulic controls that will be
used to control the work tool into the machine ECM using the monitor.
Since control inputs can be based on work tool applications and operator preference, these
inputs sometimes are not defined by the tool control system. Refer to "Control Installation
Parameter Descriptions" to determine which controls are installed on the machine.
Table 8 represents the factory default control input configurations for each tool control system.
Note: The parameters in the "DARK GRAY" cells are not displayed on the monitor.
Note: Refer to Table 8 for the specific machine model "Type #".
Table 9 shows parameters for "Type 1" through "Type 6".
Table 10 shows parameters for "Type 7" through "Bucket".
Note: Refer to the specific machine model for additional parameters.
Table 8
CONTROL ARRANGEMENT
Foot
Joystick with Joystick with 4 Foot Switch
Pedal
Modulation Switch Button (ON/OFF)
(LH)
System 3 - - - Type 9
Type 3 Type 11 Type 8
System 5 -
- (1) Type 6 (1)
System 13 and System 14
Type 1 - - -
with Medium pressure
Type 3 - - -
without Medium pressure
System 16 with Medium
Type 1 Type 10 - -
pressure
System 16 without Medium Type 8
pressure
Type 1 Type 4 - -
System 17 and System 18 Type 11 Type 8

Type 3 Type 9
without medium pressure Type 6 (1)
Type 7
Third Pump Only Type 2 Type 5 -
(1)
J2F, JJG, JHJ, RSK, W3K, MWP and A3R Machines
Table 9
Parameter
Description Type 1 Type 2 Type 3 Type 4 Type 5 Type 6
"JOYSTICK
"Modulation "Modulation "Modulation "Joystick "Joystick "Joystick
HANDLE"
Handle" Handle" Handle" Switch" Switch" Switch"
"FOOT "Not "Not "Not "Not "Not "Not

SW" Installed" Installed" Installed" Installed" Installed" Installed"
"ATCH
"Not "Not "Not "Not "Not "Not
LEFT
Installed" Installed" Installed" Installed" Installed" Installed"
PEDAL"
"ATCH
RIGHT
PEDAL"
"LEFT
"No Valve "No Valve "No Valve "Momentary "Momentary "No Valve
JOYSTICK
Controlled" Controlled" Controlled" Valve #3 Valve #3 Controlled"
#1 MODE"
Extend" Extend"
"LEFT
"No Valve "No Valve "No Valve "No Valve "No Valve "No Valve
JOYSTICK
Controlled" Controlled" Controlled" Controlled" Controlled" Controlled"
#2 MODE"
"LEFT
JOYSTICK
#4 MODE"
Retract" Retract"
"RIGHT
"Momentary "No Valve "Momentary "Momentary "No Valve "No Valve
JOYSTICK
Valve #1 Controlled" Valve #1 Valve #1 Controlled" Controlled"
#1 MODE"
Extend" Extend" Retract"
"RIGHT
JOYSTICK
#2 MODE"
"RIGHT
"No Valve "No Valve "No Valve "Momentary "No Valve "Momentary
JOYSTICK
Controlled" Controlled" Controlled" Valve #1 Controlled" Valve #1
#4 MODE"
Extend" Extend"
"FOOT SW
MODE"
"ATCH "No Valve "No Valve "No Valve "No Valve

"Attachment "Attachment
LEFT MOD Controlled" Controlled" Controlled" Controlled"
Valve #3" Valve #3"
MODE"
"ATCH
"No Valve "No Valve "No Valve "No Valve
RIGHT "Attachment "Attachment
Controlled" Controlled" Controlled" Controlled"
MOD Valve #1" Valve #1"
MODE"
"ATCH
LEFT
PEDAL
MODE"
"ATCH
RIGHT
PEDAL
MODE"
Table 10
Parameter
Description Type 7 Type 8 Type 9 Type 10 Type 11 Bucket
"JOYSTICK
"Basic "Basic "Basic "Joystick "Joystick "Basic
HANDLE"
Handle" Handle" Handle" Switch" Switch" Handle"
"Not
"FOOT "Not "Not "Installed" "Not "Not
Installed"
SW" Installed" Installed" Installed" Installed"
"ATCH "Not
"Installed" "Installed" "Not "Not "Not
LEFT Installed"
Installed" Installed" Installed"
PEDAL"
"ATCH "Not
"Not "Not "Not "Not "Not
RIGHT Installed"
Installed" Installed" Installed" Installed" Installed"
PEDAL"
"LEFT
"No Valve "No Valve "No Valve "Momentary "No Valve "No Valve
JOYSTICK
Controlled" Controlled" Controlled" Valve #3 Controlled" Controlled"
#1 MODE"
Extend"
"LEFT
JOYSTICK
#2 MODE"
"LEFT
JOYSTICK
#4 MODE"
Retract"
"RIGHT
"No Valve "No Valve "No Valve "No Valve "Momentary "No Valve
JOYSTICK
Controlled" Controlled" Controlled" Controlled" Valve #1 Controlled"
#1 MODE"
Retract"
"RIGHT
JOYSTICK
#2 MODE"
"RIGHT
JOYSTICK
#4 MODE"
Extend" Extend"
"No Valve "No Valve "Momentary "No Valve "No Valve "No Valve
"FOOT SW
Controlled" Controlled" Valve #1 Controlled" Controlled" Controlled"
MODE"
Extend"
"ATCH "No Valve "No Valve "No Valve "No Valve "No Valve "No Valve
LEFT MOD Controlled" Controlled" Controlled" Controlled" Controlled" Controlled"
MODE"
"ATCH
RIGHT
MOD
MODE"
"ATCH
LEFT "Attachment "Attachment
PEDAL Valve #3" Valve #1"
MODE"
"ATCH
RIGHT
PEDAL
MODE"
1. Enter the "Service Mode" using password "FFF2". Refer to Testing and Adjusting, "Service
Mode - Enter" for the Tool Control System for instructions on entering the service mode.
(A) Up key
(B) Right key
(C) Home key
(D) Main menu
(E) Left key
(F) Down key
(G) Cancel key
(H) OK key
2. Select "CONFIGURATION" from the "Service" menu. Press the OK key.
3. Select "CONTROL INST" from the "CONFIGURATION" menu. Press the OK key.
enter the change.
ReferenceRefer to"Control Installation Parameter Descriptions" for descriptions of each of the Tool

The following procedure will allow the user to program the electric or hydraulic controls that will be
used to control the work tool into the machine ECM using the Cat Electronic Technician.
Since control inputs can be based on work tool applications and operator preference, these
inputs sometimes are not defined by the tool control system. Refer to "Control Installation
Parameter Descriptions" to determine which controls are installed on the machine.
Table 11 represents the factory default control input configurations for each tool control system.
Note: The parameters in the "DARK GRAY" cells are not displayed on the monitor.
Note: Refer to Table 11 for the specific machine model "Type #".
Table 12 shows parameters for "Type 1" through "Type 6".
Table 13 shows parameters for "Type 7" through "Bucket".
Table 11
CONTROL ARRANGEMENT
Foot
Joystick with Joystick with 4 Foot Switch
Pedal
Modulation Switch Button (ON/OFF)
(LH)
System 3 - - - Type 9

System 5 -
- (1) Type 6 (1)
Type 1 - - -
Type 3 - - -
without Medium pressure
System 16 with Medium
Type 1 Type 10 - -
pressure
System 16 without Medium Type 8
pressure
Type 1 Type 4 - -
System 17 and System 18 Type 11 Type 8

Type 3 Type 9
without medium pressure Type 6 (1)
Type 7
Third Pump Only Type 2 Type 5 -
(1)
J2F, JJG, JHJ, RSK, W3K, MWP and A3R Machines
Table 12
Parameter
Description Type 1 Type 2 Type 3 Type 4 Type 5 Type 6
"JOYSTICK
"Modulation "Modulation "Modulation "Joystick "Joystick "Joystick
HANDLE"
Handle" Handle" Handle" Switch" Switch" Switch"
"FOOT "Not "Not "Not "Not "Not "Not

SW" Installed" Installed" Installed" Installed" Installed" Installed"
"ATCH
LEFT
PEDAL"
"ATCH
RIGHT
PEDAL"
"LEFT
JOYSTICK
#1 MODE"
Extend" Extend"
"LEFT
JOYSTICK
#2 MODE"
"LEFT
JOYSTICK
#4 MODE"
Retract" Retract"
"RIGHT
"Momentary "No Valve "Momentary "Momentary "No Valve "No Valve
JOYSTICK
Valve #1 Controlled" Valve #1 Valve #1 Controlled" Controlled"
#1 MODE"
Extend" Extend" Retract"
"RIGHT
JOYSTICK
#2 MODE"
"RIGHT
"No Valve "No Valve "No Valve "Momentary "No Valve "Momentary
JOYSTICK
Controlled" Controlled" Controlled" Valve #1 Controlled" Valve #1
#4 MODE"
Extend" Extend"
"FOOT SW
MODE"
"ATCH "No Valve "No Valve "No Valve "No Valve

"Attachment "Attachment
LEFT MOD Controlled" Controlled" Controlled" Controlled"
Valve #3" Valve #3"
MODE"
"ATCH
RIGHT "Attachment "Attachment
MOD Valve #1" Valve #1"
MODE"
"ATCH
LEFT
PEDAL
MODE"
"ATCH
RIGHT
PEDAL
MODE"
Table 13
Parameter
Description Type 7 Type 8 Type 9 Type 10 Type 11 Bucket
"JOYSTICK
"Basic "Basic "Basic "Joystick "Joystick "Basic
HANDLE"
Handle" Handle" Handle" Switch" Switch" Handle"
"Not
"FOOT "Not "Not "Installed" "Not "Not
Installed"
SW" Installed" Installed" Installed" Installed"
"ATCH "Not
"Installed" "Installed" "Not "Not "Not
LEFT Installed"
Installed" Installed" Installed"
PEDAL"
"ATCH "Not
"Not "Not "Not "Not "Not
RIGHT Installed"
Installed" Installed" Installed" Installed" Installed"
PEDAL"
"LEFT
JOYSTICK
#1 MODE"
Extend"
"LEFT
JOYSTICK
#2 MODE"
"LEFT
JOYSTICK
#4 MODE"
Retract"
"RIGHT
"No Valve "No Valve "No Valve "No Valve "Momentary "No Valve
JOYSTICK
Controlled" Controlled" Controlled" Controlled" Valve #1 Controlled"
#1 MODE"
Retract"
"RIGHT
JOYSTICK
#2 MODE"
"RIGHT
JOYSTICK
#4 MODE"
Extend" Extend"
"No Valve "No Valve "Momentary "No Valve "No Valve "No Valve
"FOOT SW
Controlled" Controlled" Valve #1 Controlled" Controlled" Controlled"
MODE"
Extend"
"ATCH "No Valve "No Valve "No Valve "No Valve "No Valve "No Valve
LEFT MOD Controlled" Controlled" Controlled" Controlled" Controlled" Controlled"
MODE"
"ATCH
RIGHT
MOD
MODE"
"ATCH
LEFT "Attachment "Attachment
PEDAL Valve #3" Valve #1"
MODE"
"ATCH
RIGHT
PEDAL
MODE"
4. Select "Configuration" from the "Service"menu.
5. Expand the list for "Control Input Installations and Configurations". Highlight the parameter to
change and click on the "Change" button on the lower left corner.
6. Select the appropriate "Control Input" for the controls installed on the machine. Press OK to
enter the change.
ReferenceRefer to "Control Installation Parameter Descriptions" for descriptions of each of the Tool
Control Installation Parameter Descriptions

Table 14
Control Installation Parameter Descriptions
Cat ET Name Monitor Name Description Explanation
Set type of joystick handle
Joystick Handle "JOYSTICK Type of joystick installed on the machine.
Configuration HANDLE" handle Type of handle:
"Basic Handle": Lever installed
on the standard machine

"Joystick Switch": Lever with 4
buttons on standard lever
"Modulation Handle": Lever
with thumb wheel and 3 buttons
Foot Switch Installation setting Set installation condition of foot

"FOOT SW"
Installation Status of foot switch switch.
Left Attachment
"ATCH LEFT Installation setting Set installation condition of left
Pedal Installation
PEDAL" of left ATT pedal ATT pedal.
Status
Right Attachment Installation setting
"ATCH RIGHT Set installation condition of
Pedal Installation of right ATT pedal
PEDAL" right ATT pedal.
Status
Set ATT valve and switching
operation to be operated by left
joystick switch #1.
"Momentary" is selected to
press and hold the switch for
Operating target of
Left Joystick Switch "LEFT JOYSTK tool activation.
left joystick switch
#1 Control Mode #1 MODE" "Toggled" is selected to press
#1
for tool activation ON and press
again for tool activation OFF.
If the handle type is "Basic
Handle", then setting is not
required.
joystick switch #2.
Operating target of
Left Joystick Switch "LEFT JOYSTK tool activation.
#2 Control Mode #2 MODE" "Toggled" is selected to press
#2
required.
Operating target of joystick switch #4.
Left Joystick Switch "LEFT JOYSTK "Momentary" is selected to
#4 Control Mode #4 MODE" press and hold the switch for
#4
tool activation.
"Toggled" is selected to press

Handle is limited to "Joystick
Switch" alone.
operation to be operated by right
joystick switch #1.
Right Joystick "RIGHT Operating target of
tool activation.
Switch #1 Control JOYSTK #1 right joystick
Mode MODE" switch #1
required.
joystick switch #2.
Right Joystick "RIGHT Operating target of
tool activation.
Switch #2 Control JOYSTK #2 right joystick
Mode MODE" switch #2
required.
joystick switch #4.
Right Joystick "RIGHT Operating target of press and hold the switch for
Switch #4 Control JOYSTK #4 right joystick tool activation.
Mode MODE" switch #4 "Toggled" is selected to press
Handle is limited to "Joystick
Switch" alone.
operation to be operated by foot
switch.
Foot Switch Control "FOOT SW Operation target of
Mode MODE" foot switch
tool activation.
Set ATT valve to be operated by

Left Joystick
"ATCH LEFT Operating target of left thumb wheel.
Thumbwheel
MOD MODE" left modulation Handle is limited to
Control Mode
"Modulation Handle" alone.
Right Joystick
"ATCH RIGHT Operating target of right thumb wheel.
Thumbwheel
MOD MODE" right modulation Handle is limited to
Control Mode
"Modulation Handle" alone.
Left Attachment "ATCH LEFT left ATT pedal.
Operating target of
Pedal Control Mode PEDAL MODE" Setting is available only when
left ATT pedal
left ATT is made set of
installation.
Right Attachment "ATCH RIGHT right ATT pedal.
Operating target of
Pedal Control Mode PEDAL MODE" Setting is available only when
right ATT pedal
right ATT is made set of
installation.
Joysticks with Modulation Switches
(1) Left Hand Joystick
(2) Left Hand Joystick Switch 1
(3) Left Hand Joystick Thumbwheel
(5) Right Hand Joystick
(6) Right Hand Joystick Switch 1
(7) Right Hand Joystick Thumbwheel
Joysticks with Three Button Switch
(1) Left Hand Joystick
(5) Right Hand Joystick
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i04939944
Work Tool Parameter - Program

SMCS - 5000-591
Work Tool Parameter Installation Procedure

Monitor Procedure
The following procedure will allow the user to program one of the ten default work tools that are
within the machine ECM using the monitor.
In order to program any of the parameters of the machine, first enter "Service Mode" on the monitor.
This procedure is described in full in Testing and Adjusting, "Service Mode - Enter" for the Tool
Control System.
Chart for the navigation which is used in order to access parameters
1. Enter the "Service Mode".
2. Select "TOOL PROGRAM" from the "Service" menu. Press the OK key.
3. The ten programmable tools are now displayed. Use the arrows to select the desired tool for
programming. Press the OK key.
enter the change.
ReferenceRefer to "Parameter Definitions" for descriptions of what the parameters control for the
work tool.
ReferenceTo view the factory parameter settings for the work tools, refer to Testing and Adjusting,

The following procedure will allow the user to program one of the ten default work tools that are
within the machine ECM using the Cat Electronic Technician.
ReferenceRefer to Testing and Adjusting, "Parameter Setting" for the individual Tool Control
Systems. This information provides specific work tool parameter settings that are common for work
tool operation.
ReferenceRefer to Testing and Adjusting, "Parameter Adjustment" for the individual Tool Control
Systems. This information provides adjustment procedures that are common to improve work tool
operation.
4. Select "Tool Configuration" from the "Service" menu.
Work tool list (typical example)
5. Highlight the tool to view or change the parameters. Click on "Configure" in the bottom right
corner of the screen.
Work tool parameter list (typical example)
6. Highlight the parameter and click on "Change" on the lower left corner of the screen to change
the parameter.
Work tool parameter list (typical example)
7. Select the desired parameter and press OK.
ReferenceRefer to "Parameter Definitions" for descriptions of what the parameters control for the
work tool.
ReferenceTo view the factory parameter settings for the work tools, refer to Testing and Adjusting,
Work Tool Parameter Descriptions

Table 1
Work Tool Parameter Descriptions
# Monitor
Cat ET Name Description Purpose / Explanation
Name
1 Tool Program Name of installing Set the tool name to display on
"Name"
Name tool monitor.
Maximum Setting of maximum
2 Upper limit value of the engine
Throttle Dial "Max Dial" value of engine speed
Position dial speed dial becomes the previously
set value when the tool was

operated.
Lower limit value of the engine
Minimum Setting of minimum
3 speed dial becomes the previously
Throttle Dial "Min Dial" value of engine speed
set value while the tool is
Position dial
selected.
Implement Enable/Disable of Priority of 2nd pump oil flow is
4 Implement
Priority Enable boom priority control given to the boom UP function
Priority
when the tool is activated
Enable/Disable of the underspeed
Enable/Disable of the
function when the tool is
5 Underspeed "Underspeed underspeed function
activated. When the underspeed
Enable Enable" when the tool is
control is set to Disable, the flow
activated
control of the pump is steady.
Enable/Disable two
6 Combiner "Combiner Allows for two pump flow to the
pump combined flow
Enable Enable" work tool.
7 One or Two One or Two Flow setting for one One way or two way flow to the
Way Flow Way or two way flow work tool is set.
When auxiliary pump is installed,
Initial Medium Setting of initial the ratio of torque reduced on the
Pressure Circuit "Init Med value of auxiliary main pump side when the tool
8
Main Pump Circuit Power pump reduction using the auxiliary pump is not
Power Red " horsepower function being operated is set. (For purpose
Reduction to prevent overload of the engine)
Total Medium Setting of overall When the tool using auxiliary

Pressure Circuit "Total Med value of auxiliary pump is operated, the ratio of
9
Main Pump Circuit Pwr pump reduction torque to be reduced on main
Power Red" horsepower function pump side is set. (For purpose to
Reduction prevent overload of the engine)
Variable Relief "Variable Rel Setting of pressure
10 Relief pressure designed to the
Valve #1 Valve #1 value of variable
tool to be installed is set.
Pressure Press" relief valve #1
Variable Relief "Variable Rel Setting of pressure
11 Relief pressure designed to the
Valve #2 Valve #2 value of variable
tool to be installed is set.
Pressure Press" relief valve #2
F2 Type Valve
"F2 Derate Setting of squeeze Target throttle pressure of spool
12 Maximum Flow
Max upper limit pressure shift pressure due to squeeze
Derate Pressure
Pressure" value function is set.
F2 Type Valve "F2 Squeeze

13 Setting of squeeze Load pressure to start the squeeze
Flow Derate Start
start pressure value function is set.
Start Pressure Pressure"
Load pressure to maximize
throttling by the squeeze function
F2 Type Valve "F2 Squeeze
14 Setting of squeeze is set. Pilot pressure is throttled to
Flow Derate End Pressure"
end pressure value the "squeeze upper limit pressure
End Pressure
value" when the load pressure
reached is the parameter value.
Setting of maximum
Multiple value of pilot Maximum value of pilot pressure
Operation "F2 Multiple pressure at at the extend side of Attachment
15
Attachment Operation attachment valve valve #1 when a multiple
Valve #1 Extend" extend side of operation is performed regardless
Extend enhanced multi of tool load pressure.
function
Setting of maximum
Multiple value of pilot Maximum value of pilot pressure
Operation "F2 Multiple pressure at at the retract side of Attachment
16
Attachment Operation attachment valve valve #1 when a multiple
Valve #1 Retract" retract side of operation is performed regardless
Retract enhanced multi of tool load pressure.
function
Maximum value of pilot pressure
Setting of maximum
at the extend side of combined
Multiple value of pilot
"CB Multiple flow valve when a multiple
17 Operation pressure at combined
Operation operation is performed regardless
Combined Flow flow valve extend
Extend" of tool load pressure. This
Valve Extend side of enhanced
parameter can be set only when
multi function
combiner flow valve is enabled.
Maximum value of pilot pressure
Setting of maximum
at the retract side of combined
Multiple value of pilot
"CB Multiple flow valve when a multiple
18 Operation pressure at combined
Operation operation is performed regardless
Combined Flow flow valve retract
Retract" of tool load pressure.This
Valve Retract side of enhanced
parameter can be set only when
multi function
combiner flow valve is enabled.
To indicate the warning on the
Hydraulic Setting of
monitor when the hydraulic oil
Temperature "Overheat temperature to start
19 temperature reached the pre-set
High Warning Event warning due to
value by setting the allowable
Event Threshold" increase of hydraulic
maximum oil temperature of the
Threshold oil temperature
installed ATT tool.
Attachment Valve #1 and #2 parameter settings
Set appropriate flow for ATT tool

to be controlled by operation of
Attachment
20 "A1 Flow Setting flow of ATT ATT valve #1.
Valve #1 Flow
Setting" valve #1 In case of combined flow, the
Setting
setting is made for total flow for
both pumps in this item.
Set additional flow in case
movement is slow when
synchronous operation of ATT
Attachment
Additional flow of tool and other movement is
Valve #1 Multi- "A1 Multi-
21 ATT valve #1 in performed.
Operation Ope Add
synchronous Do not exceed maximum flow
Additional Flow Flow"
operation requirements for work tool with
flow setting plus additional flow
setting to avoid damage to the
work tool.
This parameter improves the
accuracy when the flow is
Attachment Attachment Valve #1 calculated. The value is the
22 Valve #1 A1 Nominal Nominal Pressure for working pressure setting plus the
Nominal Pressure hydraulic pressure pressure loss of the hydraulic
Pressure loss system. Increase the desired
operating pressure for the work
tool by 2000 kPa (290 psi).
Attachment
Valve #1 One "A1 Setting of Setting of 1WAY/2WAY is made
23
Way / Two 1Way/2Way 1WAY/2WAY of depending on ATT tool to be
Way Valve Mode" ATT valve #1 installed.
Mode
Attachment Lower the parameter value of this
Valve #1 Maximum pressure at item if speed of the movement
24 "A1 Max Ext
Maximum extend side of ATT needs to be decreased when the
Press"
Extend Pressure valve #1 ATT tool was operated alone at
extend side.
25 "A1 Max Ret
Maximum retract side of ATT needs to be decreased when the
Press"
Retract Pressure valve #1 ATT tool was operated alone at
retract side.
Set time required for the spool to
Attachment
26 "A1 Open Opening time of ATT move from neutral position to
Valve #1 Open
Time" valve #1 max stroke when tool is operated.
Time
Attachment Set time required for the spool to

27 "A1 Close Closing time of ATT
Valve #1 Close move from max stroke position to
Time" valve #1
Time neutral when tool is operated.
Set direction the tool moves.
Attachment
"A1 Tool Extend/Retract Forward direction is set in
28 Valve #1 Tool
Flow direction of ATT "Normal", and reverse direction in
Flow Direction
Direction" valve #1 "Reverse" (Setting is available
only when 2WAY flow is set.)
to be controlled by operation of
ATT valve #2.
Attachment
29 "A2 Flow Setting flow of ATT However, when "Installation
Valve #2 Flow
Setting" valve #2 setting of combined pump flow
Setting
piping" is made at "V2 Combined
V1", this parameter is set at
"Setting flow of ATT valve #1"
tool and other movement is
performed.
However, when "Installation
Attachment
Additional flow of setting of combined pump flow
Valve #2 Multi "A2 Multi-
30 ATT valve #2 in piping" is made at "V2 Combined
Operation Ope Add
synchronous V1", this parameter is set at
Additional Flow Flow"
operation "Additional flow of ATT valve #1
in synchronous operation"
Do not exceed maximum flow
requirements for work tool with
work tool.
calculated. The value is the
Attachment Attachment Valve #2
working pressure setting plus the
31 Valve #2 A2 Nominal Nominal Pressure for
pressure loss of the hydraulic
Nominal Pressure hydraulic pressure
system. Increase the desired
Pressure loss
tool by
2000 kPa (290 psi).
Attachment Setting of 1WAY/2WAY is made
Valve #2 One "A2 Setting of depending on ATT tool to be
32
Way / Two 1Way/2Way 1WAY/2WAY of installed.
Way Valve Mode" ATT valve #2 However, when "Installation
Mode setting of combined pump flow

V1", this parameter is set at
"Setting of 1WAY/2WAY of
ATT valve #1"
Lower the parameter value of this
item if speed of the movement
needs to be decreased when the
ATT tool was operated alone at
Attachment
extend side.
Valve #2 Maximum pressure at
33 "A2 Max Ext However, when "Installation
Maximum extend side of ATT
Press" setting of combined pump flow
Extend Pressure valve #2
V1" and one pump flow setting,
this parameter is set at "Maximum
pressure at extend side of ATT
valve #1"
Lower the parameter value of this
item if speed of the movement
needs to be decreased when the
ATT tool was operated alone at
Attachment
retract side.
Valve #2 Maximum pressure at
34 "A2 Max Ret However, when "Installation
Maximum retract side of ATT
Press" setting of combined pump flow
Retract Pressure valve #2
this parameter is set at "Maximum
pressure at retract side of ATT
valve #1"
move from neutral position to
max stroke when tool is operated.
Attachment However, when "Installation
35 "A2 Open Opening time of ATT
Valve #2 Open setting of combined pump flow
Time" valve #2
Time piping" is made at "V2 Combined
this parameter is set at "Opening
time of ATT valve #1"
move from max stroke position to
neutral when tool is operated.
Attachment However, when "Installation
Valve #2 Close setting of combined pump flow
Time" valve #2
Time piping" is made at "V2 Combined
this parameter is set at "Closing
time of ATT valve #1"

Attachment
37 Valve #2 Tool
Flow Direction
Attachment Valve #3 and #4 parameter settings
Attachment to be controlled by operation of
38 "A3 Flow Setting flow of ATT
Valve #3 Flow ATT valve #3. Setting is not
Setting" valve #3
Setting required when ATT pump is used.

Attachment tool and other movement is
Additional flow of
Valve #3 Multi- "A3 Multi- performed. Setting is not required
39 ATT valve #3 in
Operation Ope Add when ATT pump is used.
synchronous
Additional Flow Flow" Do not exceed maximum flow
operation
work tool.
Pressure loss
tool by
2000 kPa (290 psi).
Attachment
41
Mode
42 "A3 Max Ext
Press"
extend side.
Maximum pressure at
43 Attachment "A3 Max Ret Lower the parameter value of this
Valve #3 retract side of ATT item if speed of the movement
Press"
Maximum valve #3 needs to be decreased when the
Retract Pressure ATT tool was operated alone at

retract side.
Attachment
Valve #3 Open
Time

Time" valve #3
Attachment
46 Valve #3 Tool
Flow Direction
Attachment to be controlled by operation of
47 "A4 Flow Setting flow of ATT
Valve #4 Flow ATT valve #4. Setting is not
Setting" valve #4
Setting required when ATT pump is used.

Attachment tool and other movement is
Additional flow of
Valve #4 Multi- "A4 Multi- performed. Setting is not required
48 ATT valve #4 in
Operation Ope Add when ATT pump is used.
synchronous
Additional Flow Flow" Do not exceed maximum flow
operation
work tool.
Pressure loss
tool by
2000 kPa (290 psi).
Attachment
50
Mode

51 "A4 Max Ext
Press"
extend side.
52 "A4 Max Ret
Maximum retract side of ATT needs to be decreased when the
Press"
Retract Pressure valve #4 ATT tool was operated alone at
retract side.
Attachment
Valve #4 Open
Time

Time" valve #4
Attachment
55 Valve #4 Tool
Flow Direction
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i04941592
Control (Pedal) - Calibrate

SMCS - 5000-524-P9
S/N - A3R1-UP
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - AZP1-UP
S/N - B6H1-UP
S/N - BFC1-UP
S/N - BTK1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CYD1-UP
S/N - CYW1-UP
S/N - CZF1-UP
S/N - DHE1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DTS1-UP
S/N - DTZ1-UP
S/N - EBM1-UP
S/N - EDX1-UP
S/N - EFT1-UP
S/N - EJC1-UP
S/N - EJT1-UP
S/N - ELR1-UP
S/N - ERK1-UP
S/N - ERN1-UP
S/N - FAL1-UP
S/N - FAR1-UP
S/N - FXK1-UP
S/N - GBC1-UP
S/N - GBR1-UP
S/N - GDP1-UP
S/N - GGE1-UP
S/N - GMX1-UP
S/N - GPB1-UP
S/N - GTN1-UP
S/N - HJC1-UP
S/N - J2F1-UP
S/N - JBF1-UP
S/N - JEG1-UP
S/N - JHJ1-UP
S/N - JJG1-UP
S/N - JLG1-UP
S/N - JLP1-UP
S/N - JWR1-UP
S/N - KBZ1-UP
S/N - KCE1-UP
S/N - KDJ1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KKT1-UP
S/N - KLM1-UP
S/N - LAB1-UP
S/N - LAL1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - LMG1-UP
S/N - LRM1-UP
S/N - M4T1-UP
S/N - MCH1-UP
S/N - MCL1-UP
S/N - MDE1-UP
S/N - MEY1-UP
S/N - MKR1-UP
S/N - MNB1-UP
S/N - MPG1-UP
S/N - MWP1-UP
S/N - MYG1-UP
S/N - MYP1-UP
S/N - NAS1-UP
S/N - NBD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - PAL1-UP
S/N - PBD1-UP
S/N - PBM1-UP
S/N - PGW1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - PKE1-UP
S/N - PPN1-UP
S/N - PRF1-UP
S/N - PYT1-UP
S/N - R2D1-UP
S/N - RAC1-UP
S/N - RAS1-UP
S/N - RMX1-UP
S/N - RSK1-UP
S/N - SCR1-UP
S/N - SCY1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - SYM1-UP
S/N - T2D1-UP
S/N - T2S1-UP
S/N - T2Y1-UP
S/N - TAE1-UP
S/N - TDH1-UP
S/N - THJ1-UP
S/N - TLY1-UP
S/N - TMF1-UP
S/N - TPM1-UP
S/N - TRH1-UP
S/N - W3K1-UP
S/N - WBC1-UP
S/N - WDK1-UP
S/N - WET1-UP
S/N - WGC1-UP
S/N - WLT1-UP
S/N - WNE1-UP
S/N - WRK1-UP
S/N - XBH1-UP
S/N - XCK1-UP
S/N - XDB1-UP
S/N - YDS1-UP
S/N - YFW1-UP
S/N - YSD1-UP
S/N - ZCT1-UP
S/N - ZGB1-UP
S/N - ZMF1-UP
S/N - ZML1-UP
Calibration of the attachment pedals can be performed by using two methods, calibration with the
monitor and calibration with Caterpillar Electronic Technician.
Calibration with Monitor

Note: Use the keys in the following illustration in order to calibrate the attachment pedal.
(1) Up key
(2) Right key
(3) Home key
(4) Main menu
(5) Left key
(6) Down key
(7) Cancel key
(8) OK key
Recalibration must be performed if any of the following components are replaced:
• The attachment pedal control
• The tool controller
• The software
Place the backup switch in the AUTO position.
1. In order to access the "CALIBRATION" menu, enter the "SERVICE" mode on the monitor.
2. Enter the service mode. Refer to Testing and Adjusting, "Service Mode - Enter" for the Tool
Control.
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 "CALIBRATIONS" menu option is highlighted, press the OK key (8). Refer to
Illustration 2.
5. After the OK key is pressed the "CALIBRATIONS" screen will appear. From the
"CALIBRATIONS" menu, highlight "LEVER / PEDAL / ATCH".
6. When the "LEVER / PEDAL / ATCH" option is highlighted, press the OK key (8). Refer to
Illustration 3.
7. After the OK key is pressed, the "LEVER / PEDAL / ATCH" screen should appear. Use the
down key in order to highlight "RIGHT ATCH PEDAL". Press the OK key (8) .
Note: Illustration 4 shows that the RIGHT ATCH PEDAL are highlighted. Only one of the
options will be highlighted at a time.
8. After the OK key is pressed, the monitor will begin to communicate to the ECM. When the
ECM is ready, the next screen will automatically appear.
9. Press the OK key (8) in order to start the process of calibration. After the OK key is pressed, all
inputs will be disabled.
10. Ensure that the right pedal is in the neutral position. Press OK key (8) .
11. Move the right pedal to the FORWARD position. move the right pedal to the BACKWARD
position.
12. Allow the inputs to return to the NEUTRAL position. Press the OK key (8) .
13. Press the OK key (8). Pressing the OK key enables the machine inputs.
14. The process of calibrating is completed. Press the cancel key (7) in order to exit the upper level
screen.
15. It is possible for an error to occur when you are calibrating. If an error occurs during the
process of calibrating, restart the process of calibrating.
16. Repeat Steps 7 through Step 15 for the left attachment pedal.
Calibration with Caterpillar Electronic Technician
1. The calibration initial start-up displays the following: "Left Joystick Thumbwheel Calibration",
"Right Joystick Thumbwheel Calibration", "Left Attachment Pedal Calibration" and "Right
Attachment Pedal Calibration". Perform one calibration at a time. Follow the instructions in
order to perform the calibration.
2. As the calibration is being performed, the active step will be displayed in bold text.
3. After the completion of a step, a check will appear in the completed box. Press the "NEXT"
button in order to continue to the next step of calibration.
4. When the calibration is completed, the "CALIBRATION SUCCESSFUL" screen will be

displayed.
5. The "CALIBRATION UNSUCCESSFUL" screen and an error code will be displayed if the
calibration is unsuccessful.
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i03838479
Solenoid Valve (Proportional Reducing) - Calibrate - Negative

Flow Control
SMCS - 5479
S/N - A3R1-UP
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - AZP1-UP
S/N - B6H1-UP
S/N - BFC1-UP
S/N - BTK1-UP
S/N - BYM1-UP
S/N - BYS1-UP
S/N - BZP1-UP
S/N - CJX1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - CZF1-UP
S/N - DBH1-UP
S/N - DFP1-UP
S/N - DHE1-UP
S/N - DHK1-UP
S/N - DJF1-UP
S/N - DKW1-UP
S/N - DTS1-UP
S/N - DTZ1-UP
S/N - EAH1-UP
S/N - EBM1-UP
S/N - EBY1-UP
S/N - EDX1-UP
S/N - EJC1-UP
S/N - EJT1-UP
S/N - ELR1-UP
S/N - ERK1-UP
S/N - ERN1-UP
S/N - FAL1-UP
S/N - FFK1-UP
S/N - FXK1-UP
S/N - GBC1-UP
S/N - GBR1-UP
S/N - GDP1-UP
S/N - GGE1-UP
S/N - GKL1-UP
S/N - GMX1-UP
S/N - GTN1-UP
S/N - HJC1-UP
S/N - J2F1-UP
S/N - JAT1-UP
S/N - JBF1-UP
S/N - JBT1-UP
S/N - JEG1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JHJ1-UP
S/N - JJG1-UP
S/N - JLG1-UP
S/N - JLP1-UP
S/N - JTN1-UP
S/N - JWR1-UP
S/N - JZR1-UP
S/N - KBE1-UP
S/N - KBZ1-UP
S/N - KCE1-UP
S/N - KDJ1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KKT1-UP
S/N - KLM1-UP
S/N - LAB1-UP
S/N - LAL1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - LMG1-UP
S/N - LRM1-UP
S/N - M4T1-UP
S/N - MCH1-UP
S/N - MCL1-UP
S/N - MDE1-UP
S/N - MDT1-UP
S/N - MEY1-UP
S/N - MGG1-UP
S/N - MKR1-UP
S/N - MNB1-UP
S/N - MND1-UP
S/N - MPG1-UP
S/N - MPL1-UP
S/N - MWP1-UP
S/N - MYG1-UP
S/N - MYP1-UP
S/N - NAS1-UP
S/N - NBD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - PAL1-UP
S/N - PBD1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCX1-UP
S/N - PGW1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - PPN1-UP
S/N - PRF1-UP
S/N - PYT1-UP
S/N - R2D1-UP
S/N - RAC1-UP
S/N - RAS1-UP
S/N - RMX1-UP
S/N - RSK1-UP
S/N - SCR1-UP
S/N - SCY1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - SWF1-UP
S/N - SYM1-UP
S/N - T2D1-UP
S/N - T2S1-UP
S/N - T2Y1-UP
S/N - TAE1-UP
S/N - TDH1-UP
S/N - THJ1-UP
S/N - TMF1-UP
S/N - TPM1-UP
S/N - TRH1-UP
S/N - TSN1-UP
S/N - W3K1-UP
S/N - WBC1-UP
S/N - WBN1-UP
S/N - WDK1-UP
S/N - WET1-UP
S/N - WGC1-UP
S/N - WLT1-UP
S/N - WNE1-UP
S/N - WRK1-UP
S/N - XCK1-UP
S/N - XDB1-UP
S/N - YDS1-UP
S/N - YFW1-UP
S/N - YSD1-UP
S/N - ZGB1-UP
S/N - ZMF1-UP
S/N - ZML1-UP
This calibration procedure is used in order to record the calibration data from the proportional
solenoid valve for the negative flow control. This calibration should be done at the following times:
replacement of the NFC solenoid valve, replacement of the ECM, flash new software and adjustments
to the horsepower controls on the pump.
Before this procedure is performed, ensure that the following requirements are met:
• Verify that the engine speed is properly calibrated. If necessary, see Testing and Adjusting,
"Calibration" for the Machine Electronic Control System.
• Verify that the pilot pressure is set to the proper specification that is found in Testing and
Adjusting, "Relief Valve (Pilot) - Test and Adjust" for the machine.
• Verify that the main relief valve is set to the proper specification that is found in Testing and
Adjusting, "Relief Valve (Main) - Test and Adjust" for the machine.
• Verify that the power shift pressure is properly calibrated. If necessary, see Testing and
Adjusting, "Calibration" for the Machine Electronic Control System.
There are two methods for calibrating the proportional solenoid valve for negative flow control. One
method uses a flow meter and a pressure gauge. This method is more accurate. The other method uses
only a pressure gauge. This method is less accurate. Both methods are described below.
Note: Calibration of the negative flow control valve with a flow meter is not available for System 1,
System 2, System 3 Prime and System 11. Refer to "Calibration with a Pressure Gauge".
Thumb wheel on the right joystick
The device for activation of the work tool is the thumb wheel on the right joystick for System 3,
System 5, System 13, System 14, System 16 and System 17.
Right pedal for the work tool
The device for activation of the work tool is the right pedal for System 1, System 2, System 3 Prime
and System 11.
Calibration with a Pressure Gauge and a Flow Meter

Note: When additional safety is needed on machines that are equipped with a swing brake solenoid,
disconnect the swing brake solenoid so that the swing brake remains engaged.
1. Position the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. Refer to Testing and Adjusting, "Hydraulic
System Pressure - Release" for the machine.
3. Install a 400 L (80 US gal) flow meter in the hydraulic line to the tool.
Note: Table 1 lists the parts which appear in Illustration 3.
Table 1
TOOL CHART FOR FLOW TEST
Item Number Part Number Part Description Quantity
10 4C-9910 Flow Meter 1
11 6K-6307 O-ring seal 2
12 8C-9026 Adapter 2
13 7M-8485 O-ring seal 8

4C-6482 Nipple 4
14
9U-5086 Optional Dust Cap 4
4C-6481 Coupler 4
15
9U-5084 Optional Dust Plug 4
16 4C-8767 Coupling 4
17 5P-1010 Sleeve 4
XT-5 Hose
18 5P-0201 2
3.5 m (12 ft)
19 8T-4194 Bolt 4
20 8T-4223 Hard Washer 2
21 1P-5767 Half Flange 4
22 9U-7440 Adapter 2
23 1P-3704 Rectangular Seal 2
28 6V-4143 Coupler 2
29 6V-3014 Hose 1
30 6V-3989 Nipple 1
31 8T-0861 Pressure Gauge 1
(24) Port on supply line for work tool
(25) Port on return line for work tool
(26) Pump pressure tap
(27) Pump pressure tap
(34) Load valve for flow meter
(35) Main pump
(40) Flow meter inlet
(41) Outlet of the flow meter
Flow meter
(32) Test hose from the supply line for work tool
(33) Test hose to the return line for the work tool
(34) Load valve for flow meter
(40) Flow meter inlet
(41) Outlet of the flow meter
(42) Pressure gauge for the flow meter
a. Connect one end of the test hose (32) to the supply line for the work tool (24) . Connect
the other end of the test hose (32) to the inlet port on the flow meter (40) . Refer to
Illustration 4.
b. Connect one end of the second test hose (33) to the return line for the work tool. Connect
the other end of the test hose (33) to the outlet port on the flow meter. Refer to
Illustration 4.
Pump Compartment 320D, 323D, 324D, 325D, 328D and 329D
(26) Pressure tap (idler pump pressure)
(27) Pressure tap (drive pump pressure)
(37) Pressure tap (power shift pressure)
Pump Compartment 330D and 336D
(26) Pressure tap (idler pump pressure)
(27) Pressure tap (drive pump pressure)
4. Install a 40000 kPa (5800 psi) pressure gauge (31) on pressure tap (27) .
5. Place the backup switch in the AUTO position.
7. Move the engine speed dial to position 10.
8. Increase the oil temperature to 50 °C (122 °F).
Two Pump Calibration

Use Illustration 7 in order to navigate the monitor.
(1) Up key
(2) Right key
(3) Home key
(4) Main menu
(5) Left key
(6) Down key
(7) Cancel key
(8) OK key
1. Be sure to select a work tool that provides two pump flow. Refer to Testing and Adjusting,
"Work Tool - Select" for the Tool Control System.
2. In order to access the "CALIBRATION" menu, you must first enter the "SERVICE" mode on
the monitor.
Control System.
highlighted line.
5. When the "CALIBRATIONS" menu option is highlighted, press the OK key (8) .
Typical example of the "CALIBRATIONS" screen
6. After the OK key is pressed the "CALIBRATIONS" screen will appear. From the
"CALIBRATIONS" menu, highlight "FLOW LIMIT VALVE".
7. When the "FLOW LIMIT VALVE" option is highlighted, press the OK key (8) .
8. After the OK key is pressed the "FLOW LIMIT VALVE" menu will appear. From this menu,
the following options are available:
◦ "FLOW LIMIT PRES"
◦ "2PUMP FLOW LIMIT"
9. From the "FLOW LIMIT VALVE" menu, highlight the "2PUMP FLOW LIMIT" option. When
"2PUMP FLOW LIMIT" option is highlighted, press the OK key (8) .
"CALIBRATION TITLE" screen
(L) Lower limit
(U) Upper limit
(C) Current value
(S) "STEP No:"
10. After the OK key is pressed, the "CALIBRATION TITLE" screen will appear. Refer to
Illustration 11. The "CALIBRATION TITLE" screen allows the upper limitation and the lower
limitation to be set.
Note: The title of the calibration and the name of the step will change in accordance to the
procedure that is being performed. "CALIBRATION TITLE" and "STEP NAME" are used in
this document as an example.
Note: In the "CALIBRATION TITLE" screen, "STEP No" is displayed in blue. The
"OPERATIONAL GUIDANCE" will be displayed in green.
11. The following procedure describes calibration of the monitor.
a. Perform the "2PUMP FLOW -MAX" calibration first.
b. Press the device for activation 3 times and release the device for activation 3 times.
c. Press and hold the device for activation to the OPERATING position during
calibration. Press the OK key (8) .
Note: Pressing the device for activation three times ensures that an accurate reading will
result.
d. Adjust the setting of the load valve of the flow meter (34) and observe pressure gauge
(42) . Adjust the setting until the "INDICATED PRESSURE" from Table 2 is achieved.
Pump pressure is affected by the flow and the open rate of the load valve on the flow
meter (34) . The load valve on the flow meter (34) must be adjusted when a change of
calibration is made. When you adjust the calibration value and the open rate of the load
valve on the flow meter (34) , always return the tool to the neutral position and repeat the
calibration.
If the flow is not within the proper specifications, the machine must be adjusted. Proceed
to Steps 11.e through 11.j.
e. Release the device for activation. DO NOT change the setting of the load valve on the
flow meter.
f. Press the right key (2) in order to increase the value or press the left key (5) in order to
decrease the value.
g. Press and release the device for activation 3 times.
h. Press and hold the device for activation.
i. If the "INDICATED PRESSURE", that is found in Table 2, is out of the proper range,
adjust the load valve on the flow meter (34) until the pressure gauge (42) indicates the
value in Table 2.
j. Refer to Table 2 and observe the flow meter in order to verify that the flow rate is within
the proper specification.
k. Tune the flow to the "TARGET VALUE" that is located in Table 2.
l. Repeat Step 11.e through Step 11.k until the flow rate in Step 11.k is obtained with no
adjustment of the monitor or the load valve for several repetitions.
Note: Hold the device for activation in the "OPERATION" position for a few seconds in
order to allow the hydraulic system to stabilize before repeating the Steps.
m. When the reading is within the proper range, continue to hold the device for activation in
the OPERATION position and press the OK key (8) in order to set the value.
Note: If OK key (8) is not pressed, the calibration will not be saved.
Table 2
Use
information
ITEM FOR DISPLAY that pertains to TARGET MEASURING
CALIBRATION the calibration VALUE POINT
that is being
performed.
200 ± 2
MAX FLOW L/min FLOW
(52.8 ± .5 METER
"SYSTEM 3, US gpm)
13, 14, 16, 17,
18"
320D, Use the
321D highlighted INDICATED PRESSURE
16000 kPa
CR, information 2 PUMP PRESSURE (42)
(2321 psi)
323D, for FLOW
324D calibration
with a 120 ± 2
FLOW
pressure MIN FLOW L/min
METER
gauge and a (31.7 ± 0.5
flow meter. US gpm)
INDICATED PRESSURE
16000 kPa
PRESSURE (42)
(2321 psi)
"SYSTEM 3, 220 ± 2
MAX FLOW FLOW
13, 14, 16, 17, L/min (58
METER
18" ± .5 US
Use the gpm)
325D,
highlighted
328D
information 2 PUMP INDICATED PRESSURE
CR, 16000 kPa
for FLOW PRESSURE (42)
329D (2321 psi)
calibration
with a
pressure 140 ± 2
gauge and a FLOW
MIN FLOW L/min (37
flow meter. METER
± 0.5 US
gpm)
INDICATED PRESSURE
16000 kPa
PRESSURE (42)
(2321 psi)
300 ± 2
MAX FLOW L/min FLOW
(79.3 ± .5 METER
"SYSTEM 3, US gpm)
13, 14, 16, 17,
18"
Use the
highlighted INDICATED PRESSURE
330D, 16000 kPa
information 2 PUMP PRESSURE (42)
336D (2321 psi)
for FLOW
calibration
with a 200 ± 2
FLOW
pressure MIN FLOW L/min
METER
gauge and a (52.8 ± 0.5
flow meter. US gpm)
INDICATED PRESSURE
16000 kPa
PRESSURE (42)
(2321 psi)
12. When the calibration for "MAX" flow is completed, calibrate "MIN" flow. Repeat Steps 11.b
through 11.m for the "MIN" flow.
The "2PUMP FLOW" calibration is now complete. It is possible for an error to occur when you are
calibrating. Table 3 gives some of the errors that may occur.
Table 3
Error Description of Event
$0001 ECM Fault
$0002 Active Diagnostic Present
$0003 Another Calibration is Active
$0004 Calibration Active by Another ECM
$0005 Loss of Calibration Interlock
$0006 Calibration Aborted by Tool/Monitor
$0007 Requested Display Not Supported
$0008 Unavailable Display
$0009 Calibration Aborted by ECM
$000A Calibration Failure

$000B Calibration Not Supported
$0100 Out-of-Range Low - Incr/Decr Parameter
$0101 Out-of-Range High - Incr/Decr Parameter
$0102 Invalid Action/Key Stroke Command
$0103 Calibration Value Out-of-Range
$0104 Calibration Range Too Small
$0105 Calibration Range Too Large
$0106 Calibration Value Not Saved
$1000 See Service Manual
$1010 Engine Stopped (No Engine RPM)
$1011 Engine Running (Engine RPM Present)
$1012 Engine RPM Incorrect
$1013 Engine High Idle RPM Too Fast
$1014 Engine Low Idle RPM Too Slow
$1015 Abnormal Engine RPM Signal
$1016 Speed Sensor Circuit Is Open
$1017 Service Brake Pedal Pressed
$1018 Parking Brake Not Engaged
$1019 Parking Brake Engaged
$101A Implement is Swinging/Travelling
$101B Machine Speed Not Zero
Calibration with a Pressure Gauge

Note: There are two methods for calibrating the proportional solenoid valve for negative flow control.
One method, which uses a flow meter and a pressure gauge, is more accurate. The method that is
listed below uses only a pressure gauge. This method for calibrating the proportional solenoid valve is
less accurate. This method should be used only when a flow meter is not available.
1. Be sure to select a work tool that provides two pump flow. Refer to Testing and Adjusting,
3. Before the adjustment procedure begins, lower the work tool to the ground.
4. Close the stop valves that are mounted on each side of the stick in order to prevent oil flow to
the work tool during this procedure.
320D, 323D, 324D, 325D and 329D pump compartment (top view)
(38) Pressure tap for the proportional solenoid valve for negative flow control (idler pump)
(39) Pressure tap for the proportional solenoid valve for negative flow control (drive pump)
321D CR and 328D CR pump compartment (top view)
330D and 336D pump compartment (top view)
6. Attach a 4900 kPa (750 psi) pressure gauge to the pressure tap for the proportional solenoid
valve for negative flow control (38) .
(A) Auto switch
7. Place the backup switch in the AUTO position. When AEC is active, the lamp above the auto
switch will illuminate. Refer to Illustration 15.
10. Raise the oil temperature to 50° ± 5°C (122° F).
11. Verify that the pilot pressure is set to the specifications that are in Testing and Adjusting,
"Relief Valve (Pilot) - Test and Adjust" for the machine.
12. Ensure that a "TOOL#" is selected.
13. Enter the "SERVICE" mode on the monitor. Use the following procedure to access the
"SERVICE" mode.
Buttons for controlling the monitor
(1) Up key
(2) Right key
(3) Home key
(4) Main menu key
(5) Left key
(6) Down key
(7) Cancel key
(8) OK key
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.
c. When the "SERVICE" option is highlighted, press the OK key (8) .
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 17.
highlighted line.
15. When the "CALIBRATIONS" menu option is highlighted, press the OK key (8) .
16. When the "FLOW LIMIT VALVE" option is highlighted, press the OK key (8) .
17. After the OK key is pressed the "FLOW LIMIT VALVE" menu will appear. From this menu,
the following options are available:
◦ "FLOW LIMIT PRES"
Refer to Illustration 19.
18. From the "FLOW LIMIT VALVE" menu, highlight the "FLOW LIMIT PRES" option. When
"FLOW LIMIT PRES" option is highlighted, press the OK key (8) .
"CALIBRATION TITLE" screen
(L) Lower limit
(U) Upper limit
(C) Current value
(S) "STEP No:"
19. After the OK key is pressed, the "CALIBRATION TITLE" screen allows the upper limitation
and the lower limitation to be set. Refer to Illustration 20.
"OPERATION GUIDANCE" will be displayed in green. Perform the following operation for
each "STEP No".
Illustration 21 displays the current value of pump 1 and pump 2.
20. Operate the joystick to the STICK IN position. When the stick is in the STICK IN position, the
hydraulic cylinder that controls the stick will be fully extended. Press the OK key (8) .
21. After the OK key is pressed, resume operation of the joystick to the STICK IN position. Hold
the stick in the STICK IN position during the calibration.
22. While the stick is in the STICK IN position, activate the work tool. Observe the pressure on the
gauge.
23. Use the left key (5) or the right key (2) to adjust the current level. Tune the machine to the
"LOW PRESSURE" value that is located under "TARGET VALUE" that is found in table 2.
24. When the desired value is achieved, press the OK key (8) . The monitor will automatically
begin the steps that are necessary to calibrate the "MAX" flow.
25. Move the joystick to the STICK IN position. When the stick is in the STICK IN position, the
hydraulic cylinder which controls the stick will be fully extended. Press the OK key (8) .
26. After the OK key is pressed, resume operation of the joystick to the STICK IN position. Hold
the stick in the STICK IN position during the calibration.
27. While the stick is in the STICK IN position, activate the work tool. Observe the pressure on the
gauge.
28. Use the left key (5) or the right key (2) to adjust the current level. Tune the pressure to the
"HIGH PRESSURE" value that is located under "TARGET VALUE" that is found in Table 2.
29. When the desired value is achieved, press the OK key (8) . After the OK key is pressed, the
monitor will automatically display the "SUCCEEDED" screen.
30. After completion of the calibration, press the cancel key (7) in order to exit the program.
31. It is possible for an error to occur during the calibration of the monitor. In case an error occurs,
a screen with active errors will appear. If an screen of errors should appear, the calibration will
fail and any set values that were achieved will be lost. Recalibrate the monitor. Refer to Table 4
for examples of possible errors.
Table 4
Error Description of Event
$0001 ECM Fault

$0002 Active Diagnostic Present
$0003 Another Calibration is Active
$0004 Calibration Active by Another ECM
$0005 Loss of Calibration Interlock
$0006 Calibration Aborted by Tool/Monitor
$0007 Requested Display Not Supported
$0008 Unavailable Display
$0009 Calibration Aborted by ECM
$000A Calibration Failure
$000B Calibration Not Supported
$0100 Out-of-Range Low - Incr/Decr Parameter
$0101 Out-of-Range High - Incr/Decr Parameter
$0102 Invalid Action/Key Stroke Command
$0103 Calibration Value Out-of-Range
$0104 Calibration Range Too Small
$0105 Calibration Range Too Large
$0106 Calibration Value Not Saved
$1000 See Service Manual
$1010 Engine Stopped (No Engine RPM)
$1011 Engine Running (Engine RPM Present)
$1012 Engine RPM Incorrect
$1013 Engine High Idle RPM Too Fast
$1014 Engine Low Idle RPM Too Slow
$1015 Abnormal Engine RPM Signal
$1016 Speed Sensor Circuit Is Open
$1017 Service Brake Pedal Pressed
$1018 Parking Brake Not Engaged
$1019 Parking Brake Engaged

$101A Implement is Swinging/Travelling
$101B Machine Speed Not Zero
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i03630769
Solenoid Valve (Proportional Reducing) - Calibrate

SMCS - 5479
S/N - A3R1-UP
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - AZP1-UP
S/N - B6H1-UP
S/N - BFC1-UP
S/N - BTK1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CYD1-UP
S/N - CYW1-UP
S/N - CZF1-UP
S/N - DHE1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - DTS1-UP
S/N - DTZ1-UP
S/N - EBM1-UP
S/N - EDX1-UP
S/N - EFT1-UP
S/N - EJC1-UP
S/N - EJT1-UP
S/N - ELR1-UP
S/N - ERK1-UP
S/N - ERN1-UP
S/N - FAL1-UP
S/N - FAR1-UP
S/N - FXK1-UP
S/N - GBC1-UP
S/N - GBR1-UP
S/N - GDP1-UP
S/N - GGE1-UP
S/N - GMX1-UP
S/N - GPB1-UP
S/N - GTN1-UP
S/N - HJC1-UP
S/N - J2F1-UP
S/N - JBF1-UP
S/N - JEG1-UP
S/N - JHJ1-UP
S/N - JJG1-UP
S/N - JLG1-UP
S/N - JLP1-UP
S/N - JWR1-UP
S/N - KBZ1-UP
S/N - KCE1-UP
S/N - KDJ1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KKT1-UP
S/N - KLM1-UP
S/N - LAB1-UP
S/N - LAL1-UP
S/N - LFL1-UP
S/N - LMA1-UP
S/N - LMG1-UP
S/N - LRM1-UP
S/N - M4T1-UP
S/N - MCH1-UP
S/N - MCL1-UP
S/N - MDE1-UP
S/N - MDT1-UP
S/N - MEY1-UP
S/N - MKR1-UP
S/N - MNB1-UP
S/N - MPG1-UP
S/N - MWP1-UP
S/N - MYG1-UP
S/N - MYP1-UP
S/N - NAS1-UP
S/N - NBD1-UP
S/N - NBT1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - PAL1-UP
S/N - PBD1-UP
S/N - PBM1-UP
S/N - PGW1-UP
S/N - PHX1-UP
S/N - PJP1-UP
S/N - PKE1-UP
S/N - PPN1-UP
S/N - PRF1-UP
S/N - PYT1-UP
S/N - R2D1-UP
S/N - RAC1-UP
S/N - RAS1-UP
S/N - RMX1-UP
S/N - RSK1-UP
S/N - SCR1-UP
S/N - SCY1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - SWF1-UP
S/N - SYM1-UP
S/N - T2D1-UP
S/N - T2S1-UP
S/N - T2Y1-UP
S/N - TAE1-UP
S/N - TDH1-UP
S/N - THJ1-UP
S/N - TLY1-UP
S/N - TMF1-UP
S/N - TPM1-UP
S/N - TRH1-UP
S/N - W3K1-UP
S/N - WBC1-UP
S/N - WDK1-UP
S/N - WET1-UP
S/N - WGC1-UP
S/N - WLT1-UP
S/N - WNE1-UP
S/N - WRK1-UP
S/N - XBH1-UP
S/N - XCK1-UP
S/N - XDB1-UP
S/N - YDS1-UP
S/N - YFW1-UP
S/N - YSD1-UP
S/N - ZCT1-UP
S/N - ZGB1-UP
S/N - ZMF1-UP
S/N - ZML1-UP
Use the following information in order to calibrate the solenoid valves for the attachment control
valves. Refer to Table 1 in order to identify the solenoid valves for the appropriate tool control
system.
Table 1
Identification of Solenoid Valves
Tool Control System Proportional Reducing Solenoid Valve
System 3, 5, 13, 14, 16, 17 and 18 "A1 EXTEND"
System 5, 13, 14, 17 and 18 "A1 RETRACT"
System 3, 13, 14, 16, 17 and 18 "A2 EXTEND"
System 13, 14, 17 and 18 "A2 RETRACT"
"A3 EXTEND"
Medium Pressure
"A3 RETRACT"
(1) Up key
(2) Right key
(3) Home key
(4) Main menu
(5) Left key
(6) Down key
(7) Cancel key
(8) OK key
Pump compartment
(9) Manifold for the PRV solenoids (Pressure Reducing Valve)
(10) Pressure tap for retract solenoid "A2"
(11) Pressure tap for extend solenoid "A2"
320D RR Compartment for swing motor (top view)
321D CR Compartment for swing motor (top view)
328D CR Compartment for swing motor (top view)
3. Attach a 4000 kPa (580 psi) pressure gauge to the following pressure taps: (10) , (11) , (12) and
(13) The pressure taps are located on the manifold for the PRV solenoids (9) . Attach a 4000
kPa (580 psi) pressure gauge to the following pressure taps: (14) and (15) .
4. Close the stop valves that are mounted on each side of the stick in order to prevent oil flow to
the work tool during this procedure.
7. Set the pilot pressure to the specifications in Testing and Adjusting, "Relief Valve (Pilot) - Test
and Adjust" for the machine.
8. Warm the hydraulic oil to 50 °C (122 °F).
9. Set the main relief valve to the specifications in Testing and Adjusting, "Relief Valve (Main) -
Test and Adjust" for the machine.
10. Calibrate the power shift pressure. Refer to Testing and Adjusting, "Calibration" for the
Machine Electronic Control System.
11. Set the auxiliary tool mode for two-way flow from two pumps. Refer to Testing and Adjusting,
12. In order to access the "CALIBRATION" menu, you must first enter the "SERVICE" mode on
the monitor.
Control System.
14. Press down key (6) in order to highlight the menu option "CALIBRATIONS".
15. When the "CALIBRATIONS" menu is highlighted, press the OK key (8) .
16. Press down key (6) until "CONTROL VALVE" is highlighted.
17. Press the OK key (8) .
This will bring up the "CONTROL VALVE" menu.
Calibration of Solenoid Valve for the Attachment Control

Valve
Note: The following procedure is typical for all extend solenoid valves and retract solenoid
valves.
1. Within the "CONTROL VALVE" menu, press the down key (6) in order to highlight "A1
VALVE EXTEND".
2. When the "A1 VALVE EXTEND" option is highlighted, press the OK key (8) .
3. The monitor will begin to communicate with the ECM. This may take a few moments. When
the communication link is established, the monitor will display the calibration screen.
(L) Lower limit
(U) Upper limit
(C) Current Value
(S) "STEP NUMBER" and "STEP NAME"
4. After the OK key is pressed, the "CALIBRATION TITLE" will appear. The "CALIBRATION
TITLE" screen allows the upper limitation and the lower limitation to be set. Refer to
Illustration 11.
"OPERATION GUIDANCE" will be displayed in green.
5. When a pressure gauge is connected to the pressure tap for the extend solenoid, press the OK
key (8) .
Note: The "HYD OIL TEMP / ENGINE SPEED" screens are available during the process of
calibration by pressing the up key (1) or the down key (6) .
6. Release all controls. When all controls are in the neutral position, press the OK key (8) .
7. Hold the attachment controls in the FORWARD position. Press the OK key (8) .
8. Press the right key (2) in order to increase the value. Press the left key (5) in order to decrease
the value. Adjust the value until the gauge pressure is within the specification.
9. Press the device for activation 3 times and release the device for activation 3 times.
Note: Pressing the device for activation three times ensures that an accurate reading will result.
10. Press and hold the device for activation to the FORWARD position. While you hold the device
for activation, verify that the setting is correct. If the value of the setting is not correct, repeat
Step 8 through Step 10.
11. When the value is within the specification, press the OK key (8) .
12. After the OK key is pressed the monitor will automatically continue with the tuning of the next
pressure value.
Hold the attachment controls in the FORWARD position. Press the OK key (8) .
13. Press the right key (2) in order to increase the value. Press the left key (5) in order to decrease
the value. Adjust the value until the gauge pressure is within the specification.
14. Press the device for activation 3 times and release the device for activation 3 times.
Note: Pressing the device for activation three times ensures that an accurate reading will result.
15. Press and hold the device for activation to the FORWARD position. While you hold the device
for activation, verify that the setting is correct. If the value of the setting is not correct, repeat
Step 13 through Step 15.
16. When the value is within the specification, press the OK key (8) .
17. Release all controls. When all controls are in the neutral position, press the OK key (8) .
18. The calibration is complete. Press the cancel key (7) in order to exit the process of calibration.
19. The "ERROR ID" screen will be displayed on the monitor if an error occurs. The process of
calibration will not be saved and the process must be restarted.
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i03203210
Medium Pressure: Default Value of Work Tool Parameters

SMCS - 5000
S/N - AZP1-UP
S/N - BTK1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CYW1-UP
S/N - CZF1-UP
S/N - DHE1-UP
S/N - DTZ1-UP
S/N - EBM1-UP
S/N - EDX1-UP
S/N - EFT1-UP
S/N - EJT1-UP
S/N - ELR1-UP
S/N - FAL1-UP
S/N - FAR1-UP
S/N - GBC1-UP
S/N - GDP1-UP
S/N - GMX1-UP
S/N - HJC1-UP
S/N - J2F1-UP
S/N - JAT1-UP
S/N - JWR1-UP
S/N - KBZ1-UP
S/N - KCE1-UP
S/N - KGF1-UP
S/N - KHR1-UP
S/N - KKT1-UP
S/N - KLM1-UP
S/N - LMG1-UP
S/N - MCH1-UP
S/N - MEY1-UP
S/N - MNB1-UP
S/N - MND1-UP
S/N - MPG1-UP
S/N - MWP1-UP
S/N - MYG1-UP
S/N - NBD1-UP
S/N - NES1-UP
S/N - PGW1-UP
S/N - PHX1-UP
S/N - PPN1-UP
S/N - PRF1-UP
S/N - PYT1-UP
S/N - R2D1-UP
S/N - RMX1-UP
S/N - SPN1-UP
S/N - SWF1-UP
S/N - TDH1-UP
S/N - TLY1-UP
S/N - TMF1-UP
S/N - TRH1-UP
S/N - TXA1-UP
S/N - W3K1-UP
S/N - WBC1-UP
S/N - WDK1-UP
S/N - WGC1-UP
S/N - WLT1-UP
S/N - WNE1-UP
S/N - WRK1-UP
S/N - XBH1-UP
S/N - XDB1-UP
S/N - YFW1-UP
S/N - YSD1-UP
S/N - ZMF1-UP
Note: For this system, parameters that are not shown in the tables do not affect operation of the work
tool.
Note: The parameters in the "DARK GRAY" cells do not affect the operation of the work tool.
Table 1 shows parameters for "TOOL#1" through "TOOL#5".
Table 2 shows parameters for "TOOL#6" through "TOOL#10".
Table 1
"TOOL#1" "TOOL#2" "TOOL#3" "TOOL#4" "TOOL#5"
Name Display
"TOOL PROGRAM -> GENERAL"

Name of the
"NAME" 0 0 0 0 0
tool
Maximum
position of
"MAX
the dial for 10 10 10 10 10
DIAL"
the throttle
Minimum
position of
"MIN DIAL"
the dial for 1 1 1 1 1
the throttle
Control for
"UNDER
the ENABLED ENABLED ENABLED ENABLED ENABLED
SPEED
underspeed
ENABLE"
option
Combiner
for two "COMBINER DISABLED DISABLED DISABLED DISABLED DISABLED
pump flow ENABLE"
Implement "PRIORITY
DISABLED DISABLED DISABLED DISABLED DISABLED
flow mode FLOW
control MODE"
Initial
power "INT PUMP
reduction of POWER RE" 5.0 5.0 5.0 5.0 5.0
the main
pump
Total power "TOTAL 50.0 50.0 50.0 50.0 50.0
reduction of PUMP
the main POWER RE"

pump
One-way "ONE OR
TWO-WAY TWO-WAY TWO-WAY TWO-WAY TWO-WAY
flow or two- TWO WAY"
way flow
Pressure of
the number "VAR
1 variable RELIEF #1 40000 40000 40000 40000 40000
relief valve PRES"
Pressure of
the number "VAR
2 variable RELIEF #2 40000 40000 40000 40000 40000
relief valve PRES"
Maximum
pressure of "F2 DERATE
the derate of MAX PRES" 4000 4000 4000 4000 4000
the F2 valve
Starting
pressure of "F2 SQEZ
the F2 valve START 40000 40000 40000 40000 40000
for squeeze PRES"
Ending
the F2 valve END PRES" 40000 40000 40000 40000 40000
for squeeze
Maximum
pilot
pressure for
the
"F2 MULTI
extension of
OPE 4000 4000 4000 4000 4000
attachment
EXTND"
valve during
multiple
operations
Maximum "F2 MULTI

pilot OPE 4000 4000 4000 4000 4000
pressure for RETCT"
the
retraction of
the
attachment
valve during
multiple
operations
Temperature
of the high
temperature "WARNING
warning for HYD TEMP" 126.0 126.0 126.0 126.0 126.0
the
hydraulic oil
"TOOL PROGRAM -> ATTACHMENT #1 VALVE"

Flow
settings of
the number "A1 FLOW"
0.0 0.0 0.0 0.0 0.0
1
attachment
valve
Additional
flow for the
number 1 "A1 MULTI
attachment ADD FLOW" 0.0 0.0 0.0 0.0 0.0
valve during
multiple
operation
Normal
working
pressure of "A1
the number NOMINAL 40000 40000 40000 40000 40000
1 PRES"
attachment
valve
Maximum
pressure for
the
"A1 EXTND
extension of
MAX PRES" 0 0 0 0 0
the number
1
attachment
valve
Maximum
pressure for
the
"A1 RETCT
retraction of
MAX PRES" 0 0 0 0 0
the number
1
attachment
valve
Open time
of the
"A1 OPEN
number 1 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Close time
of the
"A1 CLOSE
number 1 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Direction of
the oil flow
for the "A1 FLOW
Normal Normal Normal Normal Normal
number 1 DIRCTN"
attachment
valve
Flow
settings of
0.0 0.0 0.0 0.0 0.0
2
attachment
valve
Additional
flow for the
number 2 "A2 MULTI
valve during
multiple
operation
Normal
working "A2
pressure of NOMINAL 40000 40000 40000 40000 40000
the number PRES"
2
attachment
valve
Maximum
pressure for
the
"A2 EXTND
extension of
MAX PRES" 0 0 0 0 0
the number
2
attachment
valve
Maximum
pressure for
the
"A2 RETCT
retraction of
MAX PRES" 0 0 0 0 0
the number
2
attachment
valve
Open time
of the
"A2 OPEN
number 2 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Close time
of the
"A2 CLOSE
number 2 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Direction of
the oil flow
for the "A2 FLOW
number 2 DIRCTN"
attachment
valve
Flow
settings of
0.0 0.0 0.0 0.0 0.0
3
attachment
valve
Additional "A3 MULTI

flow for the ADD FLOW" 0.0 0.0 0.0 0.0 0.0
number 3
attachment
valve during
multiple
operation
Normal
working
pressure of "A3
3 PRES"
attachment
valve
Maximum
pressure for
the
"A3 EXTND
extension of
MAX PRES" 1400 1400 1400 1400 1400
the number
3
attachment
valve
Maximum
pressure for
the
"A3 RETCT
retraction of
MAX PRES" 1400 1400 1400 1400 1400
the number
3
attachment
valve
Open time
of the
"A3 OPEN
number 3 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Close time
of the
"A3 CLOSE
number 3 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Direction of
the oil flow
for the "A3 FLOW
number 3 DIRCTN"
attachment
valve
Table 2
"TOOL#6" "TOOL#7" "TOOL#8" "TOOL#9" "TOOL#10"

Name Display
"TOOL PROGRAM -> GENERAL"

Name of the
"NAME" 0 0 0 0 0
tool
Maximum
position of
"MAX
the dial for 10 10 10 10 10
DIAL"
the throttle
Minimum
position of
"MIN DIAL"
the dial for 1 1 1 1 1
the throttle
Control for
"UNDER
the ENABLED ENABLED ENABLED ENABLED ENABLED
SPEED
underspeed
ENABLE"
option
Combiner
for two "COMBINER DISABLED DISABLED DISABLED DISABLED DISABLED
pump flow ENABLE"
Implement "PRIORITY
DISABLED DISABLED DISABLED DISABLED DISABLED
flow mode FLOW
control MODE"
Initial
power "INT PUMP
reduction of POWER RE" 5.0 5.0 5.0 5.0 5.0
the main
pump
Total power "TOTAL
reduction of PUMP
50.0 50.0 50.0 50.0 50.0
the main POWER RE"
pump
One-way "ONE OR
TWO-WAY TWO-WAY TWO-WAY TWO-WAY TWO-WAY
flow or two- TWO WAY"
way flow
Pressure of "VAR
the number RELIEF #1 40000 40000 40000 40000 40000
1 variable PRES"
relief valve
Pressure of
the number "VAR
2 variable RELIEF #2 40000 40000 40000 40000 40000
relief valve PRES"
Maximum
pressure of "F2 DERATE
the derate of MAX PRES" 4000 4000 4000 4000 4000
the F2 valve
Starting
the F2 valve START 40000 40000 40000 40000 40000
for squeeze PRES"
Ending
the F2 valve END PRES" 40000 40000 40000 40000 40000
for squeeze
Maximum
pilot
pressure for
the
"F2 MULTI
extension of
OPE 4000 4000 4000 4000 4000
attachment
EXTND"
valve during
multiple
operations
Maximum
pilot
pressure for
the
retraction of "F2 MULTI
the OPE 4000 4000 4000 4000 4000
attachment RETCT"
valve during
multiple
operations
Temperature
of the high
temperature "WARNING
warning for HYD TEMP" 126.0 126.0 126.0 126.0 126.0
the
hydraulic oil

Flow
settings of
0.0 0.0 0.0 0.0 0.0
1
attachment
valve
Additional
flow for the
number 1 "A1 MULTI
valve during
multiple
operation
Normal
working
pressure of "A1
1 PRES"
attachment
valve
Maximum
pressure for
the
"A1 EXTND
extension of
MAX PRES" 0 0 0 0 0
the number
1
attachment
valve
Maximum
pressure for
the
"A1 RETCT
retraction of
MAX PRES" 0 0 0 0 0
the number
1
attachment
valve
Open time
of the
"A1 OPEN
number 1 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Close time
of the
"A1 CLOSE
number 1 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Direction of
the oil flow
for the "A1 FLOW
number 1 DIRCTN"
attachment
valve
Flow
settings of
0.0 0.0 0.0 0.0 0.0
2
attachment
valve
Additional
flow for the
number 2 "A2 MULTI
valve during
multiple
operation
Normal
working
pressure of "A2
2 PRES"
attachment
valve
Maximum
pressure for "A2 EXTND
the MAX PRES" 0 0 0 0 0
extension of
the number
2
attachment
valve
Maximum
pressure for
the
"A2 RETCT
retraction of
MAX PRES" 0 0 0 0 0
the number
2
attachment
valve
Open time
of the
"A2 OPEN
number 2 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Close time
of the
"A2 CLOSE
number 2 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Direction of
the oil flow
for the "A2 FLOW
number 2 DIRCTN"
attachment
valve
Flow
settings of
0.0 0.0 0.0 0.0 0.0
3
attachment
valve
Additional
flow for the
number 3 "A3 MULTI
valve during
multiple
operation
Normal "A3
working NOMINAL 40000 40000 40000 40000 40000
pressure of PRES"
the number
3
attachment
valve
Maximum
pressure for
the
"A3 EXTND
extension of
MAX PRES" 1400 1400 1400 1400 1400
the number
3
attachment
valve
Maximum
pressure for
the
"A3 RETCT
retraction of
MAX PRES" 1400 1400 1400 1400 1400
the number
3
attachment
valve
Open time
of the
"A3 OPEN
number 3 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Close time
of the
"A3 CLOSE
number 3 0.20 0.20 0.20 0.20 0.20
TIME"
attachment
valve
Direction of
the oil flow
for the "A3 FLOW
number 3 DIRCTN"
attachment
valve
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i04647875
Specifications
SMCS - 5050
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CXY1-UP
S/N - CYD1-UP
S/N - DHK1-UP
S/N - DKW1-UP
S/N - FAL1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - JPD1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - LFL1-UP
S/N - MCH1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - PHX1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - SPN1-UP
S/N - TDH1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - YSD1-UP
S/N - ZMF1-UP
Relief valve locations
(A) Boom cylinder line (rod end)
(B) Bucket cylinder line (head end)
(C) Main relief valve
(D) Stick cylinder line (head end)
(E) Boom cylinder line (head end)
(F) Bucket cylinder line (rod end)
(G) Stick cylinder line (rod end)
(H) Swing motor
(J) Swing (left)
(K) Swing (right)
(L) Pilot filter
(M) Pilot relief valve
(N) Travel motor (right)
(P) Right travel crossover relief valve for forward travel (upper valve)
(Q) Right travel crossover relief valve for reverse travel (lower valve)
(R) Left travel crossover relief valve for forward travel (upper valve)
(S) Left travel crossover relief valve for reverse travel (lower valve)
(T) Travel motor (left)
Table 1
Specifications
Torque for
Relief Valve New
Service Limit (3) Locknut
Rebuilt (2)
35000 + 500 - 1000 kPa

33000 to 35500 kPa 50 ± 10 N·m (37
(5076 + 73 - 145 psi)
(4785 to 5150 psi) ± 7 lb ft)
(C) Main relief valve
36000 + 500 - 1000 kPa
34000 to 36500 kPa 69 ± 10 N·m (51
(5221 + 73 - 145 psi)
(4930 to 5300 psi) ± 7 lb ft)
(Heavy Lift (if equipped))
(E) Boom cylinder line
(head end)
38000 + 1000 - 1500 kPa 36000 to 38500 kPa
(G) Stick cylinder line (5511 + 145 - 218 psi) (5220 to 5585 psi)
(rod end)
(A) Boom cylinder line
(rod end)
20 ± 2 N·m (14 ±
(D) Stick cylinder line 1 lb ft)
(head end)
37000 + 1500 - 1000 kPa 35000 to 37500 kPa
(B) Bucket cylinder line (5366 + 218 - 145 psi) (5075 to 5450 psi)
(head end)
(F) Bucket cylinder line
(rod end)
(K) Swing relief pressure
(right)
120 ± 10 N·m
(J) Swing relief pressure 26000 + 1000 - 1500 kPa (3770 + 145 - 218 psi)
(85 ± 7 lb ft)
(left)
(R) Left travel crossover
relief valve (forward)
(S) Left travel crossover
37500 + 1500 - 2000 kPa 34500 to 39000 kPa 130 ± 13 N·m
relief valve (reverse)
(5439 + 218 - 290 psi) (5000 to 5650 psi) (95 ± 10 lb ft)
(P) Right travel crossover
relief valve (forward)
(Q) Right travel

crossover relief valve
(reverse)
(M) Pilot relief valve 50 ± 5 N·m (36 ±

4100 ± 200 kPa (595 ± 29 psi)
4 lb ft)
(2)
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.
(3)
Performance beyond Service Limit specifications is an indication of these 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 check the engine and the pump characteristic
curve. 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".
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i05865063
Accumulator (Pilot) - Test and Charge

SMCS - 5077-045-PS; 5077-081-PS; 5077-081-PX
Pressurized System!
Hydraulic accumulators contain gas and oil under high pressure. DO

NOT disconnect lines or disassemble any component of a pressurized
accumulator. All gas pre-charge must be removed from the
accumulator as instructed by the service manual before servicing the
accumulator or any accumulator component.
Failure to follow the instructions and warnings could result in personal

injury or death.
Only use dry nitrogen gas to recharge accumulators. See your Cat
dealer for special equipment and detailed information for accumulator
service and charging.
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, "Dealer Service Tool

Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
Specification
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 1
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)
Introduction
The accumulator stores pilot pressure oil for use at the main control valves. During multiple
operations, the pilot system will demand more oil in order to maintain valve operation. The
accumulator provides pilot pressure oil to the pilot system, when the pilot pump flow is inadequate.
Inadequate flow will cause sluggish implement control.
Required Tools
Tooling (A)
This tooling group is used to test the pressure in the pilot manifold.
Table 2
Tool Item Qty Part Number Description
Pressure Gauge
A1 1 8T-0856
(0 to 6,000 kPa (0 to 870 psi))
A A2 1 6V-3989 Fitting
A3 2 6V-4143 Quick Connect Coupler
A4 1 177-7860 Hose As
F1 1 6V-3965 Fitting
F
F2 1 3J-1907 O-Ring Seal
Test Procedure
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 20 seconds 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. Refer to "Testing the Accumulator
(Nitrogen Gas Charge)".
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.
Cap for charging port on accumulator
1. Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures"

for the testing and charging procedure.
Note: If the pressure reading is within the specifications of Table 1, continue to test the operation of
the check valve within the pilot manifold. Refer to "Testing the Check Valve (Pilot Manifold)".
Testing the Check Valve (Pilot Manifold)
Typical example 1
Location of the check valve in the pilot manifold
Typical example 2
Location of the check valve in the pilot manifold
If the check valve 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 the
check valve. An improperly charged accumulator may give indications of a problem with the check
valve.
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 (800 psi) pressure gauge to port "PSA2" on the pilot manifold. Use tooling
group (A) and tooling group (F) .
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 20
seconds. This pressure 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 sudden drop 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 20 seconds, the check valve within the pilot manifold is not working
properly.
7. Move the joysticks in order to release any pilot hydraulic pressure in the accumulator.
8. Turn the start switch to the OFF position.
9. Clean the check valve. The check valve is located behind the plug on the pilot manifold. Repeat
steps 3 through 5. If the test fails, replace the check valve.
Charge Procedure
1. Refer to Special Instruction, REHS5464, "Accumulator Discharging and Charging Procedures".
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i05103389
Relief Valve (Crossover) - Test and Adjust

SMCS - 5069-036
Specification
Table 1
"Relief Valve (Crossover) - Test and Adjust"
Date Machine Serial Number
Engine Speed
Main Relief Pressure (1) Power Shift Pressure
Machine Engine speed

Settings dial "10"
35000 + 500 - 1000 kPa
2850 ± 50 kPa (415 ± 7 psi) AEC switch
(5076 + 73 - 145 psi)
OFF
Item Direction Specification Actual
Forward 37500 + 1500 - 2000 kPa (5439

+ 218 - 290 psi)
Left Travel
Reverse 37500 + 1500 - 2000 kPa (5439

+ 218 - 290 psi)
Right Travel
Forward 37500 + 1500 - 2000 kPa (5439
+ 218 - 290 psi)
Reverse 37500 + 1500 - 2000 kPa (5439

+ 218 - 290 psi)
(1)
System Pressure setting before temporary setting adjustment
Required Tools
Tooling (A) 198-4240 Digital Pressure Indicator Gp
Table 2
A 198-4240 Digital Pressure Indicator Gp
A1 1 198-4234 Indicator
Pressure Sensor
A2 1 198-4237
3447 kPa (500 psi)
Pressure Sensor
A2 2 198-4239
41,368 kPa (6,000 psi)
A3 3 198-4236 Extension Cable
D 1 418-3611 Blocker Pin
Machine Preparation
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.
Pump compartment
(1) Pressure tap (delivery pressure for drive pump)
(2) Pressure tap (delivery pressure for idler pump)
3. Connect a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (1). Use this pressure sensor to
monitor the crossover relief valve pressure setting of the right travel motor.
4. Connect a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (2). Use this pressure sensor to
monitor the crossover relief valve pressure setting of the left travel motor.
5. Connect a 3447 kPa (500 psi) pressure sensor to pressure tap (3) .
Sprocket (left travel)
(D) Blocker pin
(4) Sprocket
6. Place blocker pin (D) in sprocket (4) in order to block forward left travel. Refer to Illustration
3.
Test Procedure
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
3. Start Service Mode and input a fixed power shift pressure of 2850 kPa (415 psi).
a. Press menu key (J) .
Note: If more than 30 seconds pass between pushing the keys on the keypad, the menu
mode will be canceled 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) .
d. After OK key (l) is pressed, the screen in Illustration 5 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 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. 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: Press OK key (I) within 5 seconds after completion of Step 3.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 value. These characters represent the power shift pressure (kPa).
l. 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. The actual power shift pressure must be 2850 kPa (415 psi) on
the pressure gauge.
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.
Note: Refer to System Operation, "Monitoring System" for additional information on

Service Mode.
Travel brake valve (left side)
(18) Locknut
(19) Adjustment screw
(20) Crossover relief valve (forward left travel)
(21) Crossover relief valve (reverse left travel)
(22) Locknut
4. Slowly move the left travel control lever to full FORWARD position and check the pressure
indicator at pressure tap (2). The pressure setting of crossover relief valve (20) should be 37500
+ 1500 - 2000 kPa (5439 + 218 - 290 psi).
5. Return the left travel control lever to the NEUTRAL position.
6. In order to adjust crossover relief valve (20), loosen locknut (18) and turn adjustment screw
(19) until the pressure indicator at pressure tap (2) is 37500 + 1500 - 2000 kPa (5439 + 218 -
290 psi).
Note: Turn adjustment screw (19) clockwise in order to increase the pressure. Turn adjustment
screw (19) counterclockwise in order to decrease the pressure.
Note: Always make final pressure adjustment on pressure rise.
7. Tighten locknut (18) to a torque of 130 ± 13 N·m (95 ± 10 lb ft).
8. Place blocker pin (D1) in sprocket (4) in order to block reverse left travel.
9. Slowly move the left travel lever to full REVERSE position and check the pressure indicator at
pressure tap (2). The pressure setting of crossover relief valve (21) should be 37500 + 1500 -
2000 kPa (5439 + 218 - 290 psi).
10. Return the left travel control lever to the NEUTRAL position.
11. In order to adjust crossover relief valve (21), loosen locknut (22) and turn adjustment screw
(23) until the pressure indicator at pressure tap (2) is 37500 + 1500 - 2000 kPa (5439 + 218 -
290 psi).
Note: Turn adjustment screw (23) clockwise in order to increase the pressure. Turn adjustment
screw (23) counterclockwise in order to decrease the pressure.
In order to adjust the crossover relief valves on the right travel motor, place blocker pin (D1) in
the sprocket for right travel. Use the pressure sensor 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.
13. After relief valve adjustments, cancel Service Mode.
14. 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".
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i05259682
Travel Motor - Test - Measurement of Case Drain Oil

SMCS - 4351-081
Specification
Table 1
"Travel Motor - Test (Measurement of Case Drain Oil)"
Crossover Relief Pressure Engine Speed
Machine Settings Engine speed dial "10"
37500 ± 500 kPa (5439 ± 73 psi)
AEC switch OFF
Item Specification (1) Left Travel Right Travel
1. 1.
New Travel Motor 2. 2.
15 L/min (4.0 US gpm)
3. 3.
1. 1.
Rebuilt Travel Motor 2. 2.
3. 3.
(1)
Maximum acceptable flow
Required Tools
Tooling group (D)
Table 2
Required Tools
Part
Tool Item Qty Description
Number
Pressure Sensor
A2 1 198-4237
3447 kPa (500 psi)
Pressure Sensor
A2 1 198-4239
41,368 kPa (6,000 psi)
Flow Meter
D1 1 6V-7788
5 to 60 L/min (2 to 15 US gpm)
D2 1 8C-6874 Reducer
D3 1 6V-9746 O-Ring Seal
D4 1 124-1901 Permanent Coupling
D
D5 3 ft 122-6870 Bulk Hydraulic Hose
D6 1 124-2147 Permanent Coupling
D7 1 6V-8942 O-Ring Reducer
D8 1 6V-8556 Nut
D9 1 6V-8398 O-Ring Seal
F 1 311-1362 Vacuum Cap
G 1 418-3611 Track Block
Machine Preparation
NOTICE

containing fluids.

Cat products.
Sprocket (left travel)
(G) Track block
(1) Sprocket
2. Place track block (G) in sprocket (1) in order to block forward left travel. Refer to Illustration 3.
3. Stop the engine.
System Pressure - Release".
5. 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.
Flow Meter Tool Layout
Tooling (D)
(2) Case drain hose
(3) Connector
(4) Travel motor
6. Install the following tools in accordance with the flow meter tool layout. Refer to Illustration 4.
7. Disconnect case drain hose (2) from connector (3) .
8. Connect the flow meter assembly (D) between connector (3) and case drain hose (2) .
Note: Correct orientation of the flow meter is necessary. The oil flows from travel motor (4) to
case drain hose (2) .
9. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
Test Procedure
2. 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.
4. Move the left travel lever to full FORWARD position and check the flow of oil through the
flow meter.
5. Remove track block (G) from sprocket (1) .
6. Move the left travel lever in order to reposition the travel motor.
7. Place track block (G) in sprocket (1) in order to block forward left travel.
8. Repeat Steps 4 through 7 in order to obtain three measurements of case drain oil.
The following values specify the maximum acceptable flow of case drain oil when the travel
crossover relief valves are set at 37500 ± 500 kPa (5439 ± 73 psi).
New travel motor ... 15 L/min (4.0 US gpm)

Rebuilt travel motor ... 18 L/min (4.8 US gpm)
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i04645650
Swing Motor - Test - Measurement of Case Drain Oil

SMCS - 5058-081-ZW
Specification
Table 1
"Swing Motor - Test (Measurement of Case Drain Oil)"
Swing Relief Pressure Engine Speed
Machine Settings Engine speed dial

26000 + 1000 - 1500 kPa (3770 + 145 - 218
"10"
psi)
AEC Switch OFF
Item Specification (1) Actual
1.
New Swing Motor 2.
3.
1.
Rebuilt Swing Motor
2.
3.
(1)
Maximum acceptable flow
Required Tools
Tooling group "B"
198-4240 Digital Pressure Indicator Gp
Tooling group (D)
Table 2
Required Tools
Part
Tool Item Description Qty
Number
B 198-4240 Digital Pressure Indicator Gp
B1 198-4234 Indicator 1
Pressure Sensor
B2 198-4239 1
41,368 kPa (6,000 psi)
B3 198-4236 Extension Cable 1
Flow Meter
D1 6V-7788 1
5 to 60 L/min (2 to 15 US gpm)
D2 8C-6874 Reducer 1
D3 6V-9746 O-Ring Seal 1
D4 124-1901 Permanent Coupling 1
D
D5 122-6870 Bulk Hydraulic Hose 3 ft
D6 124-2147 Permanent Coupling 1
D7 6V-8942 O-Ring Reducer 1
D8 6V-8556 Nut 1
D9 6V-8398 O-Ring Seal 1
F 311-1362 Vacuum Cap 1
Machine Preparation
NOTICE

containing fluids.

Cat products.
1. Stop the engine.
hydraulic system.
Swing motor compartment
(1) Case drain hose
(2) Adapter
4. Disconnect case drain hose (1) from adapter (2) .
Flow Meter Tool Layout
Tooling D
(1) Case drain hose
(2) Adapter
(3) Swing motor
(4) Swivel
5. Connect the flow meter assembly (D) between adapter (2) and case drain hose (1) . Refer to
Illustration 4.
Note: Correct orientation of the flow meter is necessary. The oil flows from swing motor (3) to
swivel (4) .
6.
Pilot manifold
(5) Connector
(6) Solenoid valve for swing parking brake
7. Disconnect connector (5) from the solenoid valve for swing parking brake (6) .
8. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
Test Procedure
2. Place the engine speed dial at position "10" and AEC switch OFF.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for
engine rpm settings.
4. Slowly move the swing joystick and make sure that the swing parking brake is activated.
5. Move the swing joystick fully for 1 minute. Measure the case drain oil.
6. Stop the engine.
7. Connect connector (5) to the solenoid valve for swing parking brake (6) .
8. 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 26000 + 1000 - 1500 kPa (3770 + 145 - 218 psi).
New swing motor ... 30 L/min (7.9 US gpm)
Rebuilt swing motor ... 35 L/min (9.2 US gpm)
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i03329381
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.
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. Refer to Testing and Adjusting, "Operational Checks" for
the machine configurations that were 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".
Table 1
Required Tools
Description Qty
Measuring Tape 1
Stopwatch 1
Swing Speed (Empty Bucket)

1. Empty the bucket.
2. Position the machine on a slope of 12 degrees. Refer to Illustration 1.
3. Position the implements at maximum reach and close the bucket. Position the bucket above the
ground so that the bucket will not come in contact with any obstacles.
4. 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.
5. Measure the time that is required to swing the upper structure from position (A) to position
(B) .
6. Position the upper structure at position (C) . The upper structure should be at a 90 degree angle
to the lower structure.
7. Measure the time that is required to swing the upper structure from position (C) to position (B) .
Table 2
Swing Time (seconds)
Item New Rebuild Service Limit
Right Swing
5.2 or less 5.7 or less 6.5 or less
Left Swing
Swing Drift (Loaded Bucket)

1. Load the bucket.
Weight of bucket load
Standard Undercarriage ... 1050 kg (2310 lb)

Long Undercarriage ... 1200 kg (2640 lb)
2. Position the machine on a slope of 12 degrees. Refer to Illustration 1.
3. Position the implements at maximum reach and close the bucket. Position the bucket above the
ground so that the bucket will not come in contact with any obstacles.
4. Position the upper structure at position (A) . The upper structure should be at a 90 degree angle
(A) Upper frame
(B) Undercarriage frame
(C) Marking
5. 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.
6. Stop the engine.
7. Leave the machine in this position for three minutes. Measure the swing drift on the
circumference of the swing bearing.
9. Position the upper structure at position (C) . The upper structure should be at a 90 degree angle
10. Repeat Steps 5 through 7.
Table 3
Swing Drift mm (inch)
Item New Rebuild Service Limit
Right Swing
0 0 0
Left Swing
Shutdown SIS
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Product: EXCAVATOR

i03134340
Main Pump (Flow) - Test - Constant Horsepower Flow Control

SMCS - 5070-081-FW
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.
The electronic control module is located in the compartment behind the cab.
(1) Alarm lamp
(2) Electronic control module
(3) Monitor
(4) Message display
Note: Before starting main pump flow tests, check message display (4) on monitor (3) and alarm
lamp (1) on electronic control module (2) for normal operation. If no faults are present, perform the
operational checks. Refer to Testing and Adjusting, "Operational Checks".
Note: If the operational checks (cycle time) 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: The engine, the fuel, or the working altitude may be the problem if the operational checks
indicate that slow speed of an implement is common to both pump circuits.
Note: Perform the following procedures before testing the main pump flow.
• Set the pilot pressure to the specifications in Testing and Adjusting, "Relief Valve (Pilot) - Test
and Adjust" for the machine.
• Set the main relief valve to specifications. Refer to Testing and Adjusting, "Relief Valve
(Main) - Test and Adjust" for the machine.
• Calibrate the power shift pressure. Refer to Testing and Adjusting, "Calibration" for the
Machine Electronic Control System.
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) 9U-7335 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
(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-3703 Rectangular seal
(46) 8T-4184 Bolt
(47) 8T-4223 Hard washer
(48) 6V-0400 Half flange
(49) 1U-8292 adapter
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(9) 8T-0861 Pressure gauge
(11) Delivery line for idler pump
(12) Delivery line for drive pump
(21) Engine
(22) Multitach
(23) Drive pump
(24) Idler pump
(40) Elbow
Drive Pump
NOTICE

performance of inspection, maintenance, testing, adjusting and repair
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service

Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Note: Perform the test for the drive pump and the test for the idler pump one at a time.
Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
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) .
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) .
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 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (16) for delivery
pressure for the drive pump.
j. Install multitach group (22) on engine (21) . This is used to monitor engine speed.
Idler Pump
NOTICE

containing fluids.

Pump compartment
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
a. Disconnect delivery line (11) from idler pump (24) .
(36) on idler pump (24) by using half flanges (48) , bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
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
i. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (8) for delivery pressure
for the idler pump.
j. Install multitach group (22) on engine (21) . This is used to monitor engine speed.
Test
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.
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
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) .
d. After OK key (I) is pressed, the screen in Illustration 10 will be displayed. The password
"SERVICE" screen.
display.
high idle.
the pressure gauge.
position.

Service Mode.
4. In order to perform flow measurements for either one of the pumps, the other pump must not be
under load.
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 delivery
pressure for the drive pump or use pressure tap (8) to monitor delivery pressure for the idler
pump.
P-Q characteristic curve
Table 1
Pump Flow Test
Measuring Points
9800 kPa 15700 kPa 19600 kPa 25500 kPa 29400 kPa
(1425 (2300 psi) (2850 psi) (3700 psi) (4250 psi)
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
175 ± 5 145 ± 10 125 ± 8

New 97 ± 6 (26 92 ± 6 (24
Specification for flow (46 ± (38 ± 2.6) (33 ± 2.1)
± 1.6) ± 1.6)
rate liter/min (US 1.3)
gpm)
Service
163 (43)
limit 112 (30) 97 (26) 67 (18) 63 (17)
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
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 2350
kPa (340 psi). The output flow rate changes approximately 6 L/min (1.6 US gpm) 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.
Shutdown SIS
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Product: EXCAVATOR

i02809063
Pump Control (Output Flow) - Adjust

SMCS - 3222-025-FW
Adjust the pump output flow if the flow test results differ greatly from the specifications.
Adjustment of Pump Output Flow (Constant Horsepower

Control)
Main pump compartment
(21) Locknut
(23) Locknut
(25) Locknut
(27) 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.
1. Loosen locknut (23) .
2. Turn adjustment screw (22) in order to adjust the output flow of the pump. Turning adjustment
screw (22) clockwise will increase the output flow of the pump. Turning adjustment screw (22)
counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment screw
(22) will change the output flow of the pump at the following pressure.
◦ Output flow of the pump will change approximately 19 L/min (5.0 US gpm) if the output
flow is adjusted in the pressure range of 11800 kPa (1700 psi) to 19600 kPa (2850 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.
2. Turn adjustment screw (20) in order to adjust the output flow of the pump. Turning adjustment
screw (20) clockwise will increase the output flow of the pump. Turning adjustment screw (20)
counterclockwise will decrease the output flow of the pump. A 1/4 turn of adjustment screw
(20) will change the output flow of the pump at the following pressure.
◦ Output flow of the pump will change approximately 13 L/min (3.4 US gpm) if the output
flow is adjusted in the pressure range of 27500 kPa (4000 psi) to 34300 kPa (4950 psi).
The pump is operating in the second stage of the constant horsepower control.
Adjust the idler pump in the same manner as the drive pump. Use locknut (27) and adjustment screw
(26) in order to adjust the first stage of the constant horsepower control. Use locknut (25) and
adjustment screw (24) in order to adjust the second stage of the constant horsepower control.
Adjustment of the Maximum Output Flow of the Pump
Main pump compartment
(29) Locknut
(30) Locknut
Adjust the maximum output flow of the drive pump.
2. In order to adjust maximum output flow, turn adjustment screw (31) . Turning adjustment
screw (31) clockwise will decrease the maximum output flow of the pump. Turning adjustment
screw (31) counterclockwise will increase the maximum output flow of the pump. A 1/4 turn of
adjustment screw (31) will change the maximum output flow approximately 5 L/min (1.3 US
gpm).
Adjust the maximum output flow of the idler pump in the same manner as the drive pump. Use
locknut (29) and adjustment screw (28) in order to adjust the maximum output flow of the idler pump.
Shutdown SIS
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Product: EXCAVATOR

i03578340
Pump Control (Negative Flow) - Test

SMCS - 3222-081-FW
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.
(1) Swing motor
(3) 6V-9840 Swivel tee
(4) Makeup Line (swing motor)
(23) Drive pump
(24) Idler pump
(29) 1U-8303 Fitting
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(34) 7M-8485 O-Ring seal
(35) 4C-6481 Coupler assembly
(36) 4C-6482 Nipple assembly
(40) 6V-9854 Swivel elbow
(42) 1P-3703 Rectangular seal
(46) 8T-4184 Bolt
(47) 8T-4223 Hard washer
(48) 6V-0400 Half flange
(49) 1U-8292 Adapter
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valves
(7) Plug
(8) Pressure tap (delivery pressure for the idler pump)
(9) Pressure gauge
(15) Tees
(16) Pressure tap (delivery pressure for the drive pump)
(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

containing fluids.

Pump compartment
(16) Pressure tap (delivery pressure for the drive pump)
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
5. Install the following tools in accordance with the circuit diagram. Refer to Illustration 1 and
Illustration 2.
a. Disconnect delivery line (12) from drive pump (23) .
(36) on drive pump (23) by using half flanges (48) , bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at
h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (16) for delivery
pressure for the drive pump.
i. Install multitach group (22) on engine (21) . This is used to monitor engine speed.
Tool setup
(7) 6V-9508 Face seal plug
(15) 8T-8902 Tee
(18) 177-7860 Hose assembly
(19) Idler pump regulator
(23) Drive pump
(24) Idler pump
(25) 6V-8397 O-Ring seal
(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. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
m. Connect one end of test hose (18) to tee (15) .
n. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
o. Connect one end of test hose (44) to tee (15) .
p. Connect 6000 kPa (870 psi) pressure gauge (20) to the other end of test hose (44) .
Idler Pump
NOTICE

containing fluids.

Pump compartment
(8) Pressure tap (delivery pressure for the idler pump)
(23) Drive pump
(24) Idler pump
2. Stop the engine.
hydraulic system.
5. Install the following tools in accordance with the circuit diagram. Refer to Illustration 1 and
Illustration 2.
a. Disconnect delivery line (11) from idler pump (24) .
(36) to idler pump (24) by using half flanges (48) , bolts (46) and washers (47) .
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
g. Connect portable hydraulic tester (10) and the test hoses between nipple assembly (36) at
idler pump (24) and coupling (37) at the swing motor.
h. Connect 60000 kPa (8700 psi) pressure gauge (9) to pressure tap (8) for delivery pressure
for the idler pump.
i. Install multitach group (22) on engine (21) . This is used to monitor engine speed.
Tool setup
(7) 6V-9508 Face Seal Plug
(15) 8T-8902 Tee
(18) 177-7860 Hose Assembly
(19) Idler pump regulator
(20) 8T-0855 Pressure Gauge
(23) Drive pump
(24) Idler pump
(25) 6V-8397 O-Ring Seal
(27) 6V-9829 Cap
(28) 3J-1907 O-Ring Seal
(43) 6V-4143 Coupler
(44) Test hose
j. Disconnect negative flow control line (13) from idler pump (24) . Install seal (25) and
plug (7) to the end of negative flow control line (13) .
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) .
l. Remove 311-1362 Vacuum Cap and install the filler plug for the hydraulic tank.
m. Connect one end of test hose (18) to tee (15) .
n. Connect the other end of test hose (18) to pressure tap (14) for the power shift pressure.
o. Connect one end of test hose (44) to tee (15) .
p. Connect 6000 kPa (870 psi) pressure gauge (20) to the other end of test hose (44) .
Test

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.
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
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) .
"SERVICE" screen.
display.
high idle.
the pressure gauge.
position.

Service Mode.
(22) Multitach
(26) Valve
4. Turn valve (26) on portable hydraulic tester (10) clockwise until the pump delivery pressure is
6850 kPa (1000 psi).
5. Record the negative flow rate in Table 1.
Pressure/Flow characteristic curve
Table 1
Negative Flow Control at
2350 kPa (340 psi)
Drive pump
Oil Temperature °C (°F)
Idler pump
Engine speed (rpm) Drive pump
Idler pump
Drive pump
Flow measured liter/min (US gpm)
Idler pump
Drive pump
Flow corrected liter/min (US gpm)
Idler pump
New
100 ± 10 (26 ± 2.6)
Specification for negative flow rate liter/min (US gpm)
Service limit
80 (21)
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.
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Product: EXCAVATOR

i03327200
Pump Control (Negative Flow) - Adjust

SMCS - 3222-025-FW
Pump regulator (drive pump)
(1) Bolt
(2) Cover
(3) Seal
(4) Spring seat
(5) Spring
(6) Shim
Perform the following steps in order to adjust the drive pump.
1. Remove two bolts (1) .
2. Remove cover (2) and seal (3) .
3. Remove spring seat (4) and spring (5) .
4. Add shims (6) in order to increase the negative flow. Remove shims (6) in order to decrease the
negative flow. Refer to Table 1 for available shims and shim thickness.
Note: A change of 0.1 mm (0.0039 inch) in shim thickness will change the negative flow rate 3
L/min (0.8 US gpm) at a negative flow control pressure of 2350 kPa (340 psi).
Table 1
Available Shims
Part Number Shim Thickness
099-3669 Shim
1.00 mm (0.0394 inch)
099-6109 Shim
1.05 mm (0.0413 inch)
099-6110 Shim
1.10 mm (0.0433 inch)
099-6111 Shim
1.15 mm (0.0453 inch)
099-6112 Shim
1.20 mm (0.0472 inch)
099-6113 Shim
1.25 mm (0.0492 inch)
099-6115 Shim
1.30 mm (0.0512 inch)
099-6117 Shim
1.35 mm (0.0531 inch)
099-6118 Shim
1.40 mm (0.0551 inch)
099-6119 Shim
1.45 mm (0.0571 inch)
099-6120 Shim
1.50 mm (0.0591 inch)
099-6121 Shim
1.55 mm (0.0610 inch)
099-6122 Shim
1.60 mm (0.0630 inch)
099-6123 Shim
1.65 mm (0.0650 inch)
099-6124 Shim
1.70 mm (0.0669 inch)
099-6125 Shim
1.75 mm (0.0689 inch)
099-6126 Shim
1.80 mm (0.0709 inch)
099-6127 Shim
1.85 mm (0.0728 inch)
099-6128 Shim
1.90 mm (0.0748 inch)
099-3670 Shim
1.95 mm (0.0768 inch)
5. Install shims (6) in the pump regulator.
6. Install spring (5) . Install spring seat (4) .
7. Install cover (2) and seal (3) .
Note: Inspect seal (3) . If the seal is damaged, replace the damaged seal with a new seal.
8. Install bolts (1) . Tighten bolts (1) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
Adjust the idler pump in the same manner as the drive pump.
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Product: EXCAVATOR

i03130316
Gear Pump (Pilot) - Test

SMCS - 5085-081-GT
(1) Swing motor
(3) 6V-9840 Swivel Tee
(4) Makeup line (swing motor)
(6) 6V-9509 Face Seal Plug
(8) Pilot line (delivery line from the pilot pump)
(9) Connector at pilot pump
(10) Pilot filter
(14) Pilot pump
(30) 5K-9090 O-Ring Seal
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(34) 7M-8485 O-Ring Seal
(35) 4C-6481 Coupler Assembly
(36) 4C-6482 Nipple Assembly
(39) 6K-6307 O-Ring Seal
(40) 6V-9854 Swivel Elbow
(48) 8C-8762 Elbow
(49) 6V-8398 O-Ring Seal

NOTICE

containing fluids.

2. Stop the engine.
hydraulic system.
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(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) .
b. Remove pilot line (8) from the connector 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) .
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
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.
rpm settings.
(16) Valve (flow meter)
9. Turn valve (16) on portable hydraulic tester (7) clockwise until pressure gauge (11) on the
portable hydraulic tester shows a reading of 4100 ± 200 kPa (595 ± 29 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
36 ± 2 (9.5 ± 0.5)
Specification for pump flow liter/min (US gpm)
Service limit
30 (7.9)
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
Flow measurements must be done in pressure rise.
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Product: EXCAVATOR

i04618769
Relief Valve (Main) - Test and Adjust

SMCS - 5069-025; 5069-081
S/N - A6F1-UP
S/N - A8F1-UP
S/N - BZP1-UP
S/N - CXY1-UP
S/N - DHK1-UP
S/N - FAL1-UP
S/N - GDP1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JPD1-UP
S/N - KGF1-UP
S/N - KHN1-UP
S/N - KLM1-UP
S/N - KTF1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - TDH1-UP
S/N - WBN1-UP
Specification
Table 1
"Relief Valve (Main) - Test and Adjust"
Engine Speed
Machine Settings Speed Dial "10"
AEC switch OFF
Item Specification Actual
Main Relief 35000 + 500 - 1000 kPa (5076 + 73 - 145 psi)
Required Tools
Table 2

Pressure Sensor
A2 1 198-4239
41,368 kPa (6,000 psi)
Machine Preparation
Pump compartment
3. Attach a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (1) .
Test Procedure
rpm settings.
4. Open the bucket until the bucket cylinder rod is at the full retraction.
5. Check the main relief valve pressure setting at pressure tap (1) .
6. Return the joystick for the bucket to the NEUTRAL position.
7. The main relief valve pressure setting should be 35000 + 500 - 1000 kPa (5076 + 73 - 145 psi).
If the main relief valve pressure setting is not within the specification, adjust the main relief
valve pressure setting.
Adjustment Procedure
(5) Locknut
(6) Main relief valve
1. In order to adjust the main relief valve, loosen locknut (5) and turn adjustment screw (4) until
the pressure gauge reading at pressure tap (1) is 35000 + 500 - 1000 kPa (5076 + 73 - 145 psi).
Note: Turning adjustment screw (4) clockwise increases the pressure. Turning adjustment
screw (4) counterclockwise decreases the pressure.
Note: Always make final pressure adjustments on pressure rise.
3.
Temporary Setting of the Main Relief Valve

Note: A temporary setting of the main relief valve is required before any line relief valve can be
adjusted.
1. The main relief valve pressure setting should be 35000 + 500 - 1000 kPa (5076 + 73 - 145 psi).
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 2. Refer to Testing and
Adjusting, "Relief Valve (Main) - Test and Adjust".
Top of main control valve
(5) Locknut
(6) Main relief valve
2. Loosen locknut (5) and turn adjustment screw (4) clockwise for one half turn. Tighten locknut
(5) to the specified torque.
Shutdown SIS
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Product: EXCAVATOR

i04632529
Relief Valve (Line) - Test and Adjust

SMCS - 5117-025-L9; 5117-081-L9
S/N - A6F1-UP
S/N - A8F1-UP
S/N - A9F1-UP
S/N - BYM1-UP
S/N - BZP1-UP
S/N - CWG1-UP
S/N - CYD1-UP
S/N - DKW1-UP
S/N - GDP1-UP
S/N - GTF1-UP
S/N - JFZ1-UP
S/N - JGZ1-UP
S/N - JLG1-UP
S/N - KHN1-UP
S/N - KTF1-UP
S/N - LFL1-UP
S/N - MDE1-UP
S/N - MGG1-UP
S/N - NDE1-UP
S/N - NES1-UP
S/N - PBE1-UP
S/N - PBM1-UP
S/N - PCM1-UP
S/N - PCX1-UP
S/N - RAC1-UP
S/N - SDC1-UP
S/N - SED1-UP
S/N - WBN1-UP
S/N - WGC1-UP
S/N - WNE1-UP
S/N - YSD1-UP
S/N - ZMF1-UP
Specification
Table 1
"Relief Valve (Line) - Test and Adjust"
Main Relief Pressure (1)
Machine Settings 35000 + 500 - 1000 kPa (5076 +
73 - 145 psi)
Cylinder Cylinder Power Shift Engine Relief Pressure Setting Actual
Position Pressure Speed
Speed Dial
"10"
38000 + 1000 - 1500
Extended 2850 ± 50 kPa AEC
kPa (5511 + 145 - 218
(413 ± 7 psi) switch OFF
psi)
Boom
Speed Dial
"10"
37000 + 1500 - 1000
Retracted 2850 ± 50 kPa AEC
kPa (5366 + 218 - 145
(413 ± 7 psi) switch OFF
psi)
Speed Dial
"10"
Extended 2850 ± 50 kPa 37000 + 1500 - 1000 kPa
AEC switch
(413 ± 7 psi) (5366 + 218 - 290 psi)
OFF
Stick
Speed Dial
"10"
Retracted 2850 ± 50 kPa 38000 + 1000 - 1500 kPa
AEC switch
(413 ± 7 psi) (5511 + 145 - 218 psi)
OFF
Speed Dial
"10"
Extended 2850 ± 50 kPa 37000 + 1500 - 1000 kPa
AEC switch
(413 ± 7 psi) (5366 + 218 - 290 psi)
OFF
Bucket
Speed Dial
"10"
Retracted 2850 ± 50 kPa 37000 + 1500 - 1000 kPa
AEC switch
(413 ± 7 psi) (5366 + 218 - 290 psi)
OFF
(1)
System pressure setting before temporary setting adjustment
Required Tools
Table 2
Pressure Sensor
A2 1 198-4237
3445 kPa (500 psi)
Pressure Sensor
A3 2 198-4239
41,368 kPa (6,000 psi)
Machine Preparation
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".
2. Stop the engine.
Pump compartment
4. Connect a 41,368 kPa (6,000 psi) pressure sensor to pressure tap (1) .
6. Connect a 3445 kPa (500 psi) pressure sensor to pressure tap (3) to monitor power shift
pressure.
Test
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
Note: If more than 30 seconds pass between pushing the keys on the keypad, the menu
mode will be canceled and the previous display will be restored to message display (A) .
"SERVICE" screen.
display.
j. Place the machine controls at the following settings: engine speed dial 10 and AEC
high idle.
the pressure gauge.
position.
Note: Refer to Systems Operation, "Monitoring System" for additional information on

Service Mode.
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)
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) .
Main control valve (bottom view)
(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) .
Main control valve (bottom view)
(12) Line relief valve (stick cylinder rod end)
(13) Stick drift reduction valve
Line relief valve (12) (stick cylinder head end) is located on stick drift reduction valve (13) .
Line relief valve (typical example)
(14) Locknut
Note: Turn adjustment screw (15) clockwise in order to increase the pressure. Turn adjustment screw
(15) counterclockwise in order to decrease the pressure.
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.
Boom Cylinder
Adjustment (Boom Cylinder Head End)
Table 3
Boom Cylinder Head End
Power shift pressure

2850 ± 50 kPa (413 ± 7 psi)
Speed Dial "10"
Engine speed
AEC switch OFF
Relief pressure setting

38000 + 1000 - 1500 kPa (5511 + 145 - 218 psi)
Torque for locknut

20 ± 2 N·m (15 ± 1 lb ft)
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) .
3. Return the joystick for the boom to the NEUTRAL position.
4. The pressure gauge reading should be 38000 + 1000 - 1500 kPa (5511 + 145 - 218 psi). 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 + 1000 -
1500 kPa (5511 + 145 - 218 psi).
6. Tighten locknut (14) to 20 ± 2 N·m (15 ± 1 lb ft) on line relief valve (11) .
Adjustment (Boom Cylinder Rod End)
Table 4
Boom Cylinder Rod End

2850 ± 50 kPa (413 ± 7 psi)
Speed Dial "10"
Engine speed
AEC switch OFF

37000 + 1500 - 1000 kPa (5366 + 218 - 145 psi)
Torque for locknut

20 ± 2 N·m (15 ± 1 lb ft)
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.
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 bucket cylinder.
2. 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.
3. Check the pressure in the boom cylinder rod end on the pressure gauge at pressure tap (1) .
4. Return the joystick for the boom to the NEUTRAL position.
(7) .
6. In order to adjust line relief valve (7) , loosen locknut (14) on the boom line relief valve. Turn
1000 kPa (5366 + 218 - 145 psi).
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.
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.
Stick Cylinder
Adjustment (Stick Cylinder Rod End)
Table 5
Stick Cylinder Rod End

2850 ± 50 kPa (413 ± 7 psi)
Speed Dial "10"
Engine speed
AEC switch OFF

38000 + 1000 - 1500 kPa (5511 + 145 - 218 psi)
Torque for locknut

20 ± 2 N·m (15 ± 1 lb ft)
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.
(12) .
5. In order to adjust line relief valve (12) , loosen locknut (14) on the stick line relief valve. Turn
1500 kPa (5511 + 145 - 218 psi).
Adjustment (Stick Cylinder Head End)

Table 6
Stick Cylinder Head End

2850 ± 50 kPa (413 ± 7 psi)
Speed Dial "10"

Engine speed
AEC switch OFF

37000 + 1500 - 1000 kPa (5366 + 218 - 145 psi)
Torque for locknut

20 ± 2 N·m (15 ± 1 lb ft)
1. 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.
2. Check the pressure in the stick cylinder head end on the pressure gauge at pressure tap (2) .
3. Return the joystick for the stick to the NEUTRAL position.
(9) .
5. In order to adjust line relief valve (9) , loosen locknut (14) on the stick line relief valve. Turn
1000 kPa (5366 + 218 - 145 psi).
Bucket Cylinder
Adjustment (Bucket Cylinder Head End)
Table 7
Bucket Cylinder Head End

2850 ± 50 kPa (413 ± 7 psi)
Speed Dial "10"
Engine speed
AEC switch OFF

37000 + 1500 - 1000 kPa (5366 + 218 - 145 psi)
Torque for locknut

20 ± 2 N·m (15 ± 1 lb ft)
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) .
(8) .
5. In order to adjust line relief valve (8) , loosen locknut (14) on the bucket line relief valve. Turn
1000 kPa (5366 + 218 - 145 psi).
6. Tighten locknut (14) to 20 ± 2 N·m (177 ± 18 lb in) on line relief valve (8) .
Adjustment (Bucket Cylinder Rod End)

Table 8
Bucket Cylinder Rod End

2850 ± 50 kPa (413 ± 7 psi)
Speed Dial "10"
Engine speed
AEC switch OFF

37000 + 1500 - 1000 kPa (5366 + 218 - 145 psi)
Torque for locknut

20 ± 2 N·m (15 ± 1 lb ft)
1. 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.
2. Check the pressure in the bucket cylinder rod end on the pressure gauge at pressure tap (1) .
pressure gauge reading at pressure tap (2) is not within the specification, adjust the line relief
valve.
5. In order to adjust the line relief valve, loosen locknut (14) on the bucket line relief valve. Turn
1000 kPa (5366 + 218 - 145 psi).
6. Tighten locknut (14) to 20 ± 2 N·m (15 ± 1 lb ft) on the line relief valve.
Shutdown SIS
Previous Screen
Product: EXCAVATOR

i04645551
Relief Valve (Swing) - Test and Adjust

SMCS - 5454-036
Specification
Table 1
"Relief Valve (Swing) - Test and Adjust"
Engine Speed
Machine Settings Engine speed dial "10"
AEC switch OFF
Item Specification Actual
Right Swing 26000 + 1000 - 1500 kPa (3770 + 145 - 218 psi)
Left Swing
26000 + 1000 - 1500 kPa (3770 + 145 - 218 psi)
Required Tools
Table 2
Pressure Sensor
A2 1 198-4239
41,368 kPa (6,000 psi)
Machine Preparation
2. Stop the engine.
Pump compartment
Pilot oil manifold
(4) Connector
(5) Swing brake solenoid valve
5. Disconnect connector (4) from swing brake solenoid valve (5) .
Test Procedure
OFF.
ReferenceRefer to Testing and Adjusting, "Engine Performance - Test (Engine Speed)" for
engine rpm settings.
3. Move the swing joystick slowly and ensure that the swing parking brake is operating properly.
Swing motor
(6) Adjustment plug
(7) Locknut
(8) Relief valve (right swing)
(9) Relief valve (left swing)
(10) Adjustment plug
(11) Locknut
4. Slowly move the swing joystick for a full SWING RIGHT operation and check the pressure for
relief valve (8) at pressure tap (2) .
5. Return the swing joystick to the NEUTRAL position.
6. The pressure setting of the swing relief valve is 26000 + 1000 - 1500 kPa (3770 + 145 - 218
psi). If the pressure reading at pressure tap (2) is not within the specification, adjust the swing
relief valve.
7. In order to adjust the swing relief valve, loosen locknut (7) . Turn adjustment plug (6) until the
pressure gauge reading at pressure tap (2) is 26000 + 1000 - 1500 kPa (3770 + 145 - 218 psi).
Note: Turning adjustment plug (6) clockwise increases the pressure. Turning adjustment plug
(6) counterclockwise decreases the pressure.
9. Slowly move the swing joystick for a full SWING LEFT operation and check the pressure for
relief valve (9) at pressure tap (2) .
10. Return the swing joystick to the NEUTRAL position.
11. The pressure setting of the swing relief valve is 26000 + 1000 - 1500 kPa (3770 + 145 - 218
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 (11) . Turn adjustment plug (10) until
the pressure gauge reading at pressure tap (2) is 26000 + 1000 - 1500 kPa (3770 + 145 - 218
psi).
Note: Turning adjustment plug (10) clockwise increases the pressure. Turning adjustment plug
(10) counterclockwise decreases the pressure.
14. After completing the test and/or the adjustment procedures for the swing relief valves, stop the
engine.
16. Connect connector (4) to the solenoid valve for swing parking brake (5) .

Testing and Adjusting Hydraulic System

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320D Excavator BZP00001-UP (MACHINE) POWERED BY C6.4 Engine(SEBP5228 - ...

Testing and Adjusting

Engine Performance - Test - Engine Speed

1. Position the machine on level ground.

2. Stop the engine.

3. Install 9U-7400 Multitach Tool Group on the engine.

4. Start the engine.

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

Testing and Adjusting

Engine Speed - Check

9U-7400 Multitach Tool Gp

Testing and Adjusting

Engine Performance - Test - Engine Speed

1. Position the machine on level ground.

2. Stop the engine.

3. Install 9U-7400 Multitach Tool Group on the engine.

4. Start the engine.

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

Testing and Adjusting

Cooling System - Check - Overheating

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve

5. Check the radiator.

8. Check for loose drive belts.

a. Make a visual inspection of the exhaust system.

Testing and Adjusting

Cooling System - Inspect

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve

1. Check the coolant level in the cooling system.

2. Look for leaks in the system.

4. Inspect the drive belts for the fan.

5. Check for damage to the fan blades.

6. Look for air or combustion gas in the cooling system.

Testing and Adjusting

Cooling System - Test

Cooling system pressure at specific altitudes and boiling points of water

At operating temperature, engine coolant is hot and under pressure.

Cooling System Conditioner contains alkali. Avoid contact with skin

Test location for water temperature

Test Tools For The Cooling System

9S-8140 Pressurizing Pump 1

When working on an engine that is running, avoid contact with hot

4C-6500 Digital Thermometer

9U-7400 Multitach Tool Group

9S-8140 Pressurizing Pump

245-5829 Coolant/Battery Tester Gp

Making the Correct Antifreeze Mixtures

Checking the Filler Cap

Typical schematic of filler cap

At operating temperature, engine coolant is hot and under pressure.

Cooling System Conditioner contains alkali. Avoid contact with skin

◦ Surface for seal

3. Install the pressure cap on the 9S-8140 Pressurizing Pump .

4. Observe the exact pressure that opens the filler cap.

6. If the filler cap is damaged, replace the filler cap.

Testing The Radiator And Cooling System For Leaks

Part Number Part Name Qty

At operating temperature, engine coolant is hot and under pressure.

Cooling System Conditioner contains alkali. Avoid contact with skin

3. Put the 9S-8140 Pressurizing Pump onto the radiator.

5. Check the radiator for leakage on the outside.

◦ You do NOT observe any leakage after five minutes.

◦ The dial indicator remains constant beyond five minutes.