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YDRAULIC AND ELE
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Bienvenido: r120jr6
Producto: NO SE HA ESCOGIDO NINGUN EQUIPO
Modelo: NO SE HA ESCOGIDO NINGUN EQUIPO
Configuración: NO SE HA ESCOGIDO NINGUN EQUIPO
Pruebas y ajustes
320, 320 L y 320 N, y 320 S EXCAVADORAS HIDRÁULICAS Y ELE.
Número de medio -SENR6044-02 Fecha de publicación -09/09/1994 Fecha de actualización -12/10/2001
Pruebas y ajustes
Introducción
Este manual contiene información sobre los procedimientos de solución de problemas de los sistemas de control
electrónico e hidráulico en las excavadoras 320, 320 L, 320 N y 320 S. Este manual está dividido en las
siguientes tres secciones principales:
1. Pruebas y ajustes del sistema electrónico

2. Procedimientos de verificación
3. Pruebas y ajustes del sistema hidráulico
NOTA: Como regla general, si existe alguna duda sobre la causa de un problema, primero debe verificar el
sistema electrónico.
Referencia: Para obtener información sobre el funcionamiento del sistema eléctrico de lo anterior, haga
referencia a: "Operación de sistemas, sistema electrónico", formulario SENR6048 o formulario SENR5404. Para
obtener información sobre el funcionamiento del sistema hidráulico de lo anterior, haga referencia a:
"Funcionamiento de sistemas, sistema hidráulico", formulario SENR6043 o formulario SENR5455.
Para obtener información sobre la solución de problemas de los componentes del motor, consulte el módulo
"Funcionamiento, comprobación y ajuste de sistemas, componentes básicos del motor 3306", formulario
SENR5546 o "Funcionamiento, comprobación y ajuste de sistemas, componentes básicos del motor 3114 y 3116
motores", formulario SENR3583.
Procedimientos de verificación
En cada procedimiento de verificación, se supone que el funcionamiento del motor es normal a menos que se
especifique lo contrario.
Sistema de control electronico

El monitor y el controlador electrónico son los componentes principales del sistema de control electrónico. El
monitor y el controlador electrónico tienen una función de autodiagnóstico. Las comprobaciones de
autodiagnóstico del monitor, el controlador electrónico y la línea de comunicación entre ellos son los primeros
pasos a la hora de solucionar problemas en el sistema electrónico.
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Los indicadores de alarma de acción en el panel del monitor, alertan a un operador sobre un problema en el
sistema electrónico. El programa de servicio del controlador "Modo de datos" también se puede usar para
identificar los problemas (consulte la sección de este módulo "Modo de datos"). Si el programa de servicio se
activa durante el funcionamiento de la máquina, los problemas que son monitoreados por el sistema de
monitoreo se indican en la pantalla de caracteres. Si el programa de servicio se activa cuando se detiene el
funcionamiento de la máquina, todos los problemas existentes y anteriores (problemas que no se han corregido)
se indican en la pantalla de caracteres. Para activar el programa de servicio del controlador "Modo de datos",
consulte la sección "Modo de datos" en este módulo.
Pruebas operacionales
Si la pantalla del sistema de control de la unidad de alimentación electrónica indica que está funcionando
correctamente, realice las pruebas operativas. Opere la máquina siguiendo los procedimientos descritos en la
sección "Pruebas y ajustes del sistema hidráulico". Compare los resultados de las pruebas operativas con las
especificaciones para determinar la extensión del problema. En las pruebas operativas, es importante determinar
si la fuerza hidráulica o la velocidad del implemento es un problema que se extiende a toda la máquina o solo
con una operación específica.
Si hay fallas en los circuitos entre las bombas principal o piloto y las válvulas de control, el rendimiento general
de la máquina disminuirá. Este tipo de problema en el sistema hidráulico no es detectado por las funciones de
autodiagnóstico del sistema de control electrónico descrito anteriormente (no hay indicación de alarma de acción
en la pantalla de caracteres). Para detectar tal problema, es necesario verificar las características de flujo de las
bombas, la presión de alivio principal, la presión del piloto, etc.
Programa de servicio
Panel de monitor electronico
(1) Indicador de temperatura del refrigerante del motor. (2) Indicador de combustible. (3) Lámpara de acción. (4) Pantalla de personaje. (5)
Panel de monitores. (6) Medidor de temperatura del aceite hidráulico. (7) Interruptor selector de modo de trabajo. (8) Indicador del
calentador de aire (solo máquinas 2DL y 9KK). (9) Indicador de alarma de carga. (10) Indicador de alarma de temperatura del refrigerante
del motor. (11) Indicador de alarma de temperatura del aceite hidráulico. (12) Indicador de alarma de presión de aceite del motor. (13)
Indicador de alarma del controlador. (14) Indicador de alarma del monitor. (15) Indicador de prioridad del brazo de modo de trabajo. (16)
Indicador de prioridad de giro del modo de trabajo. (17) Interruptor selector de modo de energía. (18) Indicador del modo de potencia III.
(19) Indicador de modo de potencia II. (20) Indicador I del modo de encendido. (21) Indicador de control fino de modo de trabajo. (22)
Interruptor de luz. (23) Indicador de luz 1. (24) Indicador de luz 2. (25) Indicador del limpiaparabrisas 2. (26) Indicador de velocidad de
viaje ALTA (conejo). (27) Indicador de velocidad de viaje BAJA (tortuga). (28) Interruptor de control de velocidad de desplazamiento.
(29) Indicador AEC. (30) Panel de interruptores. (31) Conmutador AEC. (32) Indicador del limpiaparabrisas 1. (33) Indicador de lavadora.
(34) Interruptor de la lavadora. (35) Interruptor del limpiaparabrisas. (36) Interruptor de cancelación de alarma. (37) Interruptor de
servicio. (38) Indicador de cancelación de alarma.
Introducción
El panel del monitor electrónico se activa y muestra la salida recibida del controlador electrónico. El programa
de servicio del controlador electrónico se divide en dos modos de programa. Cada modo de programa tiene una
función particular como sigue:
1. Modo de datos;
Este modo de programa contiene ocho modos de función y proporciona la información necesaria para que
el mecánico determine la condición de la máquina.
2. Modo de calibración;
Este modo de programa contiene diez modos de función y proporciona información utilizada para ajustar
y confirmar las funciones del sistema / componente después de reemplazar los componentes del sistema de
control electrónico. Este nivel de programa también se usa para ayudar al mecánico a solucionar
problemas de la máquina.
Para activar las funciones del modo de programa de servicio, use los interruptores de control provistos en el
panel del monitor electrónico.
NOTA: Las lecturas de caracteres inesperadas debidas a la operación aleatoria de los interruptores no deben
tenerse en cuenta.
Para seleccionar el modo de función deseado, primero inicie un modo de programa de servicio adecuado
(consulte la sección "Inicio del modo de datos" y / o " Modo de calibración" Puesta en marcha "). A
continuación, opere los interruptores de control según lo especificado, hasta que la información deseada se
indique en la pantalla de caracteres.
Cuando la función de programa de servicio seleccionada ya no sea necesaria, utilice el procedimiento adecuado
(consulte la sección "Procedimiento de parada del modo de datos" y / o " Modo de calibración Detener
Procedimiento ") para cancelar.
Modo de datos
NOTA: La activación del programa de servicio "Modo de datos" no afecta a los controles y operaciones de la
máquina, excepto por lo siguiente:
Los indicadores LED para el interruptor de modo de alimentación, el interruptor de control de velocidad de
desplazamiento, el interruptor de luz y el interruptor de limpiaparabrisas se encienden solo en modo intermitente
durante la activación del programa de servicio "Modo de datos".
El modo de datos contiene los siguientes modos de función que proporcionan ocho categorías de información.
1. Presión de cambio de potencia.

2. Velocidad del motor.
3. Temperatura del refrigerante del motor.
4. Temperatura del aceite hidráulico.

5. Conversión A / D (analógica / digital).
6. Error en tiempo real.
7. Entrada digital.
8. Pantalla de control de salida.
Modo de inicio de datos
Panel del monitor electrónico (modo de inicio de datos)

(4) Pantalla de caracteres. (17) Interruptor selector de modo de energía. (18) Indicador del modo de potencia III. (36) Interruptor de
cancelación de alarma. (38) Indicador de cancelación de alarma.
NOTA: Para acceder y ver las ocho funciones disponibles en el "Modo de datos", el motor puede estar
funcionando o apagándose. Si el motor está funcionando, las ocho funciones del modo de datos se pueden ver
como valores operativos. Si el motor no está funcionando, el interruptor de arranque debe estar en la posición
"ENCENDIDO".
1. Mantenga presionado el interruptor de cancelación de alarma (36) hasta que el indicador de cancelación de
alarma (38) comience a parpadear.
2. Mientras se presiona el interruptor de cancelación de alarma (36), presione el interruptor selector de modo de
energía (17) hasta que el indicador de modo de energía III (18) comience a destellar. Suelte el interruptor de
cancelación de alarma (36) y el interruptor selector de modo de energía (17).
3. El programa de servicio "Modo de datos" ahora está activado y la pantalla de caracteres (4) mostrará el primer
valor del modo de función (presión de cambio de potencia).
NOTA:
Si el interruptor (17) se mantiene presionado demasiado tiempo, la visualización de caracteres se secuenciará a

través de los ocho modos de función disponibles en el programa "Modo de datos".
Selección de función de modo de datos
Panel de monitor electrónico (Selección de función de modo de datos)

cancelación de alerta.
1. Presione repetidamente el primer interruptor de cancelación de alarma (36) y luego el interruptor del modo de
encendido (17) hasta que aparezca el modo de función deseado en la pantalla de caracteres (4).
2. Cada vez que se presionan ambos interruptores, el modo de función cambia en una secuencia de números en
aumento de los ocho modos de función de manera repetitiva.
3. Al mismo tiempo que se muestra el carácter del modo de función, se enciende el indicador de interruptor
correspondiente. Para determinar el modo de función seleccionado, busque el indicador de interruptor que está
parpadeando.
NOTA: Si se presiona el interruptor de cancelación de alarma (36) durante más de 2 segundos, el modo de datos
se detiene y la pantalla de caracteres (4) muestra la posición de marcación rápida del motor.
NOTA: El acceso a las "Funciones del modo de datos" debe realizarse en la secuencia que se muestra en el
siguiente cuadro.
Cada una de las ocho funciones del modo de datos tiene una luz indicadora designada. La siguiente tabla
muestra las ocho funciones del modo de datos y sus luces indicadoras designadas:
Presión de cambio de potencia
Panel del monitor electrónico (presión de cambio de potencia)

cancelación de alarma.
Cuando se selecciona este modo de función, el indicador de modo de potencia III (18) parpadea. La pantalla de
caracteres (4) muestra "P" en la primera posición y la presión de cambio de potencia real en la segunda y tercera
2 2
posición. La unidad de presión de cambio de potencia está en kgf / cm . 1 kgf / cm es aproximadamente igual
a 100 kPa (14 psi).
La velocidad del motor
Panel del monitor electrónico (Velocidad del motor)

(4) Pantalla de caracteres. (19) Indicador de modo de potencia II.
Cuando se selecciona este modo de función, el indicador de modo de potencia II (19) parpadea. La pantalla de
caracteres (4) mostrará la velocidad del motor en rpm, independientemente de la carga de la máquina.
Multiplique los valores de rpm en la visualización de caracteres (4) por 10 para determinar las rpm reales.
Temperatura de anticongelante
Panel del monitor electrónico (Temperatura del refrigerante del motor)

(4) Pantalla de caracteres. (20) Indicador I del modo de encendido.
Cuando se selecciona este modo de función, el indicador de modo de alimentación I (20) parpadea. La pantalla
de caracteres (4) muestra la temperatura del refrigerante del motor dentro de un rango de 14 ° C a 127 ° C (57 °
F a 260 ° F). Las unidades de temperatura del refrigerante del motor se muestran en incrementos de 1 ° C (1.8 °
F). Si la lectura de la pantalla de caracteres está por debajo de 0 ° C, la primera posición en la pantalla de
caracteres lee "-".
NOTA: La pantalla de caracteres (4) muestra la temperatura del refrigerante del motor en grados centígrados.
Temperatura del aceite hidráulico
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Panel de monitor electrónico (Temperatura del aceite hidráulico)

(4) Pantalla de caracteres. (23) Indicador de luz 1.
Cuando se selecciona este modo de función, el indicador de luz 1 (23) parpadea. La pantalla de caracteres (4)
muestra la temperatura del aceite hidráulico dentro de un rango de 14 ° C a 127 ° C (57.2 ° F a 260.6 ° F). Las
unidades de temperatura del aceite hidráulico se muestran en incrementos de 1 ° C (1.8 ° F).
NOTA: La pantalla de caracteres (4) muestra la temperatura del aceite hidráulico en grados Celsius.
Conversión A / D (Analógica / Digital)
Panel de monitor electrónico (conversión A / D)

(4) Visualización de caracteres. (24) Indicador de luz 2.
Cuando se selecciona el modo de función de conversión analógica / digital, el indicador de la luz 2 (24)
parpadea. La pantalla de caracteres (4) muestra la información analógica de ocho funciones de la máquina. Se
necesita una tabla de conversión para comprender la información digital indicada. Descripción de las ocho
funciones de la máquina omitidas ya que esta información no es necesaria para el servicio o el diagnóstico.
Códigos de error en tiempo real
Panel del monitor electrónico (códigos de error en tiempo real)

(4) Visualización de caracteres. (26) Indicador de velocidad de viaje ALTA (conejo).
Cuando se selecciona este modo, el indicador de velocidad de viaje HIGH (conejo) (26) parpadea. La pantalla de
caracteres (4) muestra los códigos para los problemas que han ocurrido. Se muestran en una secuencia de
números en aumento según la "Lista de problemas" que se muestra a continuación, de manera repetitiva. Un
código de visualización de caracteres permanece en pantalla durante 2 segundos con un intervalo de 1 segundo
entre los códigos.
NOTA: Un código de visualización de [E00] indica que no hay errores de sistema.
NOTA: Vaya a la "Tabla de secuencia electrónica" adecuada para solucionar el problema de [E33] de acuerdo
con lo siguiente:
Entrada digital
Panel de monitor electrónico (entrada digital)
(4) Pantalla de caracteres. (7) Interruptor de modo de trabajo. (17) Interruptor selector de modo de energía. (27) Indicador de velocidad de
viaje BAJA (tortuga). (36) Interruptor de cancelación de alarma.
Cuando se selecciona este modo, el indicador de velocidad de viaje BAJA (tortuga) (27) parpadea. Este modo
muestra 21 tipos de información en la pantalla de caracteres (4).
1. Presione y mantenga presionado el interruptor de cancelación de alarma (36) y luego presione el interruptor
de modo de energía (17) hasta que parpadee el indicador de velocidad de viaje LOW (tortuga) (27). Suelte el
interruptor de cancelación de alarma (36) y el interruptor de modo de alimentación (17).
2. La pantalla de caracteres (4) mostrará [0 9] o [010]. La primera posición de carácter "0" indica que este es el
primero de los 21 "puertos" o tipos de información adicionales. El "9" indica el código del arnés de cableado
para las excavadoras de 320 y 320 L con motor 3066. El "10" indica el código del arnés de cableado para las
excavadoras 320, 320 L, 320 N y 320 S con motor 3116.
3. Para secuenciar a través de los 21 "puertos", primero presione y mantenga presionado el interruptor de
cancelación de alarma (36) y luego presione el interruptor de modo (7) hasta que la pantalla de caracteres lea el
"puerto" deseado.
NOTA: Este modo es capaz de proporcionar un total de 21 tipos de información. Ocho de los 21 "puertos" (tipos
adicionales de información) son de repuesto.
La siguiente tabla proporciona una lista de los 21 "puertos" y sus componentes:
NOTA: Los puertos "0" y "1" no dan ninguna indicación de "[O n] o [o F] en la pantalla de caracteres.
Ejemplos típicos:
[0 9]: indica el modelo de máquina de la excavadora "320" o "320 L" con motor 3066. Si aparece un código
diferente en la segunda y tercera posición, verifique que el circuito esté bien conectado a tierra.
[010]: indica el modelo de máquina de "320", "320 L", "320 N" o "320 S" excavadora con motor 3116. Si
aparece un código diferente en la segunda y tercera posición, verifique que el circuito esté bien conectado a
tierra.
[1 1]: El dial de velocidad del motor está en la posición "1".
[110]: El dial de velocidad del motor está en la posición "10".
[1Er]: hay un problema en la marcación rápida o el circuito del motor entre la marcación rápida y el controlador.
(Er: error)
[2En]: El interruptor de presión de desplazamiento está en ON.
[2oF]: El interruptor de presión de desplazamiento está apagado.
NOTA: Para revisar el interruptor de presión de viaje, active el control de viaje con el interruptor de presión en
la posición ON. Si la pantalla de caracteres no lee [2On], es una indicación de un posible problema en el
interruptor de presión de viaje y / o su circuito.
Pantalla de control de salida
Panel de monitor electrónico (pantalla de control de salida)

(4) Pantalla de caracteres. (32) Indicador del limpiaparabrisas 1.
Cuando se selecciona este modo de función, el indicador del limpiaparabrisas 1 (32) parpadea. La pantalla de
caracteres (4) muestra el código que representa la salida actual de la bomba. El código inicial mostrado será
[L00] para un control de salida de bomba normal. El código de visualización de caracteres permanece encendido
durante 2 segundos con un intervalo de 0,5 segundos entre los códigos.
Ejemplos típicos:
[L00]: El control de salida es normal.
[LA]: Control de salida de la bomba cuando el sensor de retroalimentación del accionador del regulador es
anormal.
[L b]: Control de la bomba a una temperatura del aceite hidráulico demasiado baja.
NOTA: [L b] se muestra solo cuando uno de los controles está activado.
NOTA: Durante la función de "Pantalla de control de salida", el sistema AEC y el ralentí de un solo toque no se
activan. El interruptor de marcación de velocidad del motor controla la velocidad del motor solo en condiciones
sin carga.
Referencia: Para obtener más información sobre el control de salida de la bomba, consulte el módulo
"Funcionamiento de sistemas, Sistema electrónico", Formulario No. SENR6048 o Formulario No. SENR5404.
Procedimiento de parada de modo de datos
Panel de monitor electrónico (Procedimiento de parada)

(4) Pantalla de caracteres. (36) Interruptor de cancelación de alarma.
Utilice cualquiera de los dos métodos siguientes.
1. Gire el interruptor de arranque del motor a la posición de APAGADO.
2. Mantenga presionado el interruptor de cancelación de alarma (36) al menos 2 segundos hasta que la pantalla
de caracteres (4) muestre la posición de marcación rápida del motor.
Modo de calibracion
NOTA: Los procedimientos para cada función en " Modo de calibración"son independientes entre sí. No es
necesario que el motor esté funcionando para todas las funciones que se enumeran en el siguiente cuadro. El
siguiente cuadro enumera las funciones en" Modo de calibración "y si el motor debe estar funcionando para cada
una de las funciones:
Modo de calibracion Puesta en marcha
Panel de monitor electrónico ( modo de calibración)Puesta en marcha)

(1) Indicador de temperatura del refrigerante del motor. (2) Indicador de combustible. (3) Lámpara de acción. (4) Pantalla de personaje. (6)
Medidor de temperatura del aceite hidráulico. (8) Indicador del calentador de aire (solo máquinas 2DL y 9KK). (9) Indicador de alarma de
carga. (10) Indicador de alarma de temperatura del refrigerante del motor. (11) Indicador de alarma de temperatura del aceite hidráulico.
(12) Indicador de alarma de presión de aceite del motor. (13) Indicador de alarma del controlador. (14) Indicador de alarma del monitor.
(37) Interruptor de servicio.
DARSE CUENTA
Antes de iniciar el modo de calibración, el interruptor de velocidad del
motor debe estar en la posición de dial "1" y el interruptor de
arranque del motor debe estar en la posición OFF.
1. Presione el interruptor de servicio (37) y arranque el motor. Como se muestra en la tabla anterior, no es
necesario arrancar el motor para obtener información para ciertas funciones en el " Modo de calibración".".
2. Continúe presionando el interruptor de servicio (37) hasta que la lámpara de acción (3) se encienda y la
pantalla de caracteres (4) muestre [20H] o [20C]. Todos los indicadores de alarma excepto la pantalla de
caracteres (4) se apagarán.
3. El " modo de calibración""ahora se accede a él y la pantalla de caracteres (4) muestra la primera de las 10
funciones (números de modelo de la máquina y el motor) como se muestra en la tabla anterior. La lámpara de
acción (3) permanece ENCENDIDA durante todos los modos de función de calibración.
NOTA: La activación del " Modo de calibración " anula la función del indicador de temperatura del refrigerante
del motor (1), el indicador de combustible (2), la lámpara de acción (3), el indicador de temperatura del aceite
hidráulico (6), el indicador del calentador de aire (8), la alarma de carga indicador (9), indicador de alarma de
temperatura del refrigerante del motor (10), indicador de alarma de la temperatura del aceite hidráulico (11),
indicador de alarma de presión del aceite del motor (12), indicador de alarma del controlador (13) e indicador de
alarma del monitor (14).
Modo de calibracion Selección de funciones
Panel de monitor electrónico (selección de función)

(3) Lámpara de acción. (4) Pantalla de personaje. (17) Interruptor selector de modo de energía. (22) Interruptor de luz. (28) Interruptor de
control de velocidad de desplazamiento. (31) Conmutador AEC. (35) Interruptor del limpiaparabrisas.
El interruptor selector de modo de energía (17), el interruptor de luz (22), el interruptor AEC (31), el interruptor
del limpiaparabrisas (35) y el interruptor de control de velocidad de desplazamiento (28) se presionan cada vez
para obtener uno de los diez modos de función.
Maquina y modelo de motor
Panel de monitor electrónico (modelo de máquina y motor)

(4) Pantalla de caracteres. (17) Interruptor selector de modo de energía. (18) Indicador de Modo de potencia III.
1. Iniciar " Modo de calibración". Consulte la sección" Arranque del modo de calibración ".
Al acceder al " Modo de calibración ", la máquina y el modelo del motor son las primeras funciones a las que se
accede. Para obtener esta función nuevamente después de ver o acceder a cualquiera de las otras funciones,
presione el interruptor selector de modo de energía (17) hasta que se encienda el indicador de Modo III de
energía (18).
2. La pantalla de caracteres (4) muestra [20H] para una excavadora "320" o "320 L" con motor 3066. La pantalla
de caracteres (4) muestra [20C] para una excavadora "320", "320 L", "320 N" o "320 S" con motor 3116.
La primera y segunda posición de la pantalla de caracteres (4) muestra el código del modelo de excavadora. La
tercera posición de la pantalla de caracteres (4) muestra el código para el modelo del motor.
3. Detener el " modo de calibración""(a menos que se desee otra selección de función). Consulte la sección"
Procedimiento de parada del modo de calibración ".
NOTA: La activación del " Modo de calibración " anula la función AEC y mantiene la presión de cambio de
potencia constante en un nivel de presión equivalente a una condición sin carga. El interruptor de dial de
velocidad del motor funciona normalmente.
Versión de software del controlador / monitor
Panel del monitor electrónico (versión de software del controlador / monitor)

(4) Pantalla de caracteres. (17) Interruptor selector de modo de energía. (19) Indicador de modo de potencia II. (31) Conmutador AEC.
2. Presione el interruptor selector de modo de energía (17) hasta que se encienda el indicador de Modo II de
energía (19).
3. La pantalla de caracteres (4) muestra [17C], por ejemplo. El "17" en la pantalla de caracteres representa un
número de dos dígitos particular del software para cada modo de máquina. La "C" representa el controlador.
4. Para determinar la versión de software del monitor, presione el interruptor AEC (31). La pantalla de caracteres
(4) muestra [20P] por ejemplo. El "20" en la pantalla de caracteres representa un número de dos dígitos
particular del software para cada modo de máquina. La "P" representa la versión del software.
NOTA: Cada vez que se presiona el interruptor AEC (31), la pantalla de caracteres alternará entre los dos
códigos de software [17C] y [20P], por ejemplo.
Registro de errores
Panel de monitor electrónico (Registro de errores)

(4) Pantalla de caracteres. (17) Interruptor selector de modo de energía. (20) Indicador de modo de energía I. (28) Interruptor de control de
velocidad de desplazamiento. (31) Conmutador AEC. (34) Interruptor de la lavadora.
2. Presione el interruptor selector de modo de energía (17) hasta que se encienda el indicador de Modo I (20).
3. La pantalla de caracteres (4) muestra [Hd]. Esta pantalla indica que se puede ver la lista de códigos de error
almacenados. El controlador tiene una función continua de autodiagnóstico durante el funcionamiento de la
máquina. El controlador almacenará códigos de error si se detecta una falla, incluso una falla intermitente. La
lista de códigos de error se almacena en el historial de errores en sistemas importantes hasta que se borra la
memoria.
4. Los códigos de error se visualizan en la pantalla de caracteres en orden ascendente o descendente. Cada vez
que se presiona el interruptor AEC (31), la lista secuencial ascendente de códigos de error almacenados se
muestra como se muestra en el siguiente ejemplo:
[Hd]
[F6]
[F10]
[F40]
[F41]
[Fin]
5. Cada vez que se presiona el interruptor de la lavadora (34), la lista secuencial descendente de códigos de error
almacenados se muestra como se muestra en el siguiente ejemplo:
[Fin]
[F41]
[F40]
[F10]
[F6]
[Hd]
NOTA: Una "F" en la primera posición de la pantalla de caracteres (4) representa un código de error
almacenado (historial de errores). Una "E" en la primera posición de la pantalla de caracteres (4) representa un
código de error en tiempo real.
6. Para borrar los códigos de error y el historial de errores, mantenga presionados durante tres segundos
aproximadamente los siguientes tres botones:
* Interruptor AEC (31)

* Interruptor selector de modo de energía (17)
* Interruptor de control de velocidad de viaje (28)
7. Los códigos de error se borran de la memoria del historial de errores cuando la pantalla de caracteres (4)
muestra [CLr] y luego vuelve a mostrar [Hd].
Referencia: para obtener una lista de códigos de error, consulte la sección en este módulo "Modo de datos,
códigos de error en tiempo real".
NOTA: La información sobre un problema se almacena en este modo de función hasta que se completa el
procedimiento de eliminación correcto. Siempre borre el historial de errores después de que se haya corregido el
problema.
NOTA: La activación del modo de registro de errores anula la función del sistema AEC y mantiene la presión de
cambio de potencia constante en el nivel de presión sin carga. El dial de velocidad del motor funciona
normalmente.
8. Detener " Modo de calibración"(a menos que se desee otra selección de función). Consulte la sección"
NOTA: Los siguientes códigos de registro de error no se muestran en la pantalla de caracteres durante la
activación de este modo de calibración .
F1 a F5, F7, F9, F12, F15, F32, F34, F37, F38, F39 y F48.
NOTA: Activación del " Modo de calibración""anula la función AEC y mantiene constante la presión de cambio
de potencia en un nivel de presión equivalente a una condición sin carga. El interruptor de marcación rápida del
motor funciona normalmente.
Prueba de salida digital
Panel de monitor electrónico (Prueba de salida digital)

(4) Pantalla de caracteres. (22) Interruptor de luz. (23) Indicador de luz 1. (29) Indicador AEC. (31) Conmutador AEC. (33) Indicador de
lavadora. (34) Interruptor de la lavadora. (36) Interruptor de cancelación de alarma.
2. Presione el interruptor de la luz (22) hasta que se encienda el indicador de la luz 1 (23).
3. La pantalla de caracteres (4) muestra [0oF] que representa el primero de los 10 componentes que se pueden
probar. Hay 16 "puertos" disponibles de las conexiones eléctricas para varios componentes de salida del
controlador (similar a la información de "Entrada digital" a la que se accede en "Modo de datos"). Seis de los
"puertos" son repuestos. El código en la primera posición de la pantalla de caracteres representa el "puerto"
particular de cada componente.
Los "puertos" y sus componentes se muestran en el siguiente cuadro:
4. Cada vez que se presiona el interruptor AEC (31), aparece un código de puerto diferente en la pantalla de
caracteres (4) en orden ascendente. Presione el interruptor de la lavadora (34) para ver los puertos en orden
descendente.
5. Presione el interruptor de cancelación de alarma (36) para encender o apagar el componente de cada puerto.
La pantalla de caracteres (4) se muestra como se muestra en la tabla anterior a medida que se activa o desactiva
cada puerto. Si ocurre una sobrecorriente en un componente, la pantalla de caracteres (4) muestra [0Er].
Válvula reductora proporcional prueba de barrido
Conector del compartimiento del colector de aceite piloto (39).
1. Detenga el motor y desconecte el conector (39) de la válvula reductora proporcional.
2. Conecte el arnés de prueba al conector (39).
Compartimiento de la bomba principal

(40) Grifo de presión de cambio de potencia.
3. Instale un manómetro de presión de 4900 kPa (700 psi) en la llave de presión de cambio de potencia (40).
4. El interruptor de respaldo de la bomba debe estar en la posición "AUT".
NOTA: El motor debe estar en funcionamiento para obtener información precisa para esta prueba.
6. Caliente el aceite hidráulico a la temperatura normal de funcionamiento.
7. Haga funcionar el motor a las rpm máximas sin carga.
8. Todos los controles deben estar en la posición NEUTRAL.
Panel del monitor electrónico (Prueba de barrido proporcional de la válvula reductora)

(4) Pantalla de caracteres. (22) Interruptor de luz. (24) Indicador de luz 2.
9. Inicie la "Prueba de barrido proporcional de la válvula reductora" de la siguiente manera:
a. Presione el interruptor de la luz (22) hasta que se encienda el indicador de la luz 2 (24).
segundo. La columna izquierda de la pantalla de caracteres (4) muestra la letra "P". La "P" en la primera
columna indica que la válvula reductora proporcional está siendo probada.
NOTA: El propósito de esta función es verificar si la válvula reductora proporcional se está activando con una
señal de corriente del controlador. Cuando se selecciona esta función, la segunda y tercera columna en la
pantalla de caracteres (4) cambian en una secuencia de números ascendente de 0 a 32. El rango de un ciclo de 0
a 32 toma aproximadamente cinco segundos. Las secuencias de visualización de caracteres (4) forman [P 0] a
[P32].
10. Mientras se realiza la "Prueba de barrido PRV", monitoree el multímetro y el manómetro de 4900 kPa (700
psi).
La lectura del multímetro cambia dentro de un rango de 0.16 a 0.63 amperios en aproximadamente cinco
segundos. El manómetro en la llave de presión de cambio de potencia (40) varía simultáneamente de 0 a 3150
kPa (0 a 455 psi).
NOTA: Durante la "Prueba de barrido PRV", el multímetro y el medidor de presión deben realizar un ciclo de
aumento o disminución uniforme (sin "picos" o cambios rápidos). Además, durante la activación de este modo
de función, las funciones AEC no se activan, pero la marcación rápida se activa normalmente.
Cambio de velocidad del motor

NOTA: Esta prueba es útil para medir las velocidades del motor sin carga en incrementos de 20 a 30 rpm, desde
las posiciones LOW IDLE de fábrica presentes hasta HIGH IDLE del interruptor de marcación rápida del
gobernador. Esta prueba es adecuada para pruebas de medición de nivel de ruido.
Panel del monitor electrónico (cambio de velocidad del motor)
(4) Pantalla de caracteres. (29) Indicador AEC. (31) Conmutador AEC. (32) Indicador del limpiaparabrisas 1. (33) Indicador de lavadora.
(34) Interruptor de la lavadora. (35) Interruptor del limpiaparabrisas.
2. Presione el interruptor del limpiaparabrisas (35) hasta que se encienda el indicador del limpiaparabrisas 1
(32).
3. Coloque el selector de velocidad del regulador en la mejor posición para el requisito de la prueba (la posición
que se acerque más a la configuración deseada de rpm del motor).
4. Presione el interruptor AEC (31) para aumentar las rpm del motor, y presione el interruptor de la lavadora (34)
para disminuir las rpm del motor. Cada vez que se presiona el interruptor AEC (31), el indicador AEC (29) se
enciende. Cada vez que se presiona el interruptor de la lavadora (34), se enciende el indicador de la lavadora
(33).
5. La visualización de caracteres (4) se incrementará en 1 (10 rpm).
NOTA: Esta prueba permite que la señal de comando de presión de cambio de potencia permanezca constante a
un nivel de presión deseado. La señal de comando de presión de cambio de potencia constante es necesaria para
permitir que se realicen los procedimientos de prueba y ajuste para alinear las válvulas de alivio y también
realizar las pruebas de "PQ" de la bomba.
Presión de cambio de potencia fija

NOTA: Esta prueba permite que la señal de comando de presión de cambio de potencia permanezca constante a
un nivel de presión deseado. La señal de comando de presión de cambio de potencia constante es necesaria para
permitir que se realicen los procedimientos de prueba y ajuste para alinear las válvulas de alivio y también
realizar las pruebas de "PQ" de la bomba.
Panel del monitor electrónico (presión de cambio de potencia fija)

(4) Pantalla de caracteres. (25) Indicador del limpiaparabrisas 2. (31) Conmutador AEC. (34) Interruptor de la lavadora. (35) Interruptor
del limpiaparabrisas. (36) Interruptor de cancelación de alarma.
2. Presione el interruptor del limpiador (35) hasta que se encienda el indicador del limpiador 2 (25).
3. La pantalla de caracteres (4) mostrará "P" en la primera posición y la presión de cambio de potencia
seleccionada en la segunda y tercera posición. Como ejemplo, el valor que se muestra en la pantalla de
2 2
caracteres (4) de [P25] está en kgf / cm . Para convertir kgf / cm a kPa, multiplique el valor que se muestra en
la pantalla de caracteres (4) por 100. La presión de cambio de potencia resultante es de 2450 kPa (355 psi).
4. Presione el interruptor AEC (31) para aumentar la señal de comando de presión de cambio de potencia en 1
2 2
kgf / cm dentro de un rango de 3 a 30 kgf / cm [290 a 2950 kPa (42 a 430 psi)].
5. Presione el interruptor de la lavadora (34) para disminuir la señal de comando de presión de cambio de
2 2
potencia en 1 kgf / cm dentro de un rango de 3 a 30 kgf / cm [290 a 2950 kPa (42 a 430 psi)].
NOTA: Al presionar el interruptor de cancelación de alarma (36), la pantalla de caracteres (4) se muestra
alternativamente entre la presión de cambio de potencia y las rpm del motor.
NOTA: Consulte "Cambio de velocidad del motor" para determinar el valor de la velocidad del motor que se
muestra en la pantalla de caracteres (4).
Comprobación de la configuración de la marcación rápida del motor

NOTA: Esta prueba se usa para verificar que el valor de posición del interruptor de dial de velocidad del motor
seleccionado cumple con el valor de configuración de velocidad del motor de fábrica.
Panel del monitor electrónico (Comprobación de configuración de la marcación rápida del motor)
(4) Pantalla de caracteres. (26) Indicador HIGH (Conejo) de velocidad de desplazamiento. (28) Interruptor de control de velocidad de
desplazamiento.
2. Presione el interruptor de control de la velocidad de viaje (28) hasta que se encienda el indicador HIGH
(Conejo) de la velocidad de viaje (26).
3. La pantalla de caracteres (4) muestra la característica del valor de rpm del motor al ajuste de la posición del
interruptor de marcación rápida del motor.
NOTA: Activación del " Modo de calibración""anula la función AEC y mantiene constante la presión de cambio
de potencia en un nivel de presión equivalente a una condición sin carga. El interruptor de marcación rápida del
motor funciona normalmente.
Calibración del actuador del regulador automático (G / A)
DARSE CUENTA
La temperatura del aceite hidráulico debe estar a la temperatura de
funcionamiento normal antes de realizar este procedimiento de
calibración.
NOTA: Este procedimiento debe realizarse cada vez que se reemplace o reinstale el actuador o controlador del
regulador.
NOTA: La activación de este modo anula la función del sistema AEC y mantiene la presión de cambio de
potencia constante en el nivel de presión sin carga. El dial de velocidad del motor se puede colocar en cualquier
posición ya que no se puede activar hasta que se haya completado la calibración del actuador del gobernador. El
interruptor de respaldo del gobernador debe estar en la posición AUT (no de respaldo).
Electronic Monitor Panel (Automatic Governor Actuator Calibration)

(4) Character display. (26) Travel speed HIGH (Rabbit) indicator. (28) Travel speed control switch. (31) AEC switch. (34) Washer switch.
(36) Alarm cancel switch.
1. Start "Calibration Mode". See the section, "Calibration Mode Start-up".
2. Depress travel speed control switch (28) until travel speed HIGH (Rabbit) indicator (26) comes ON.
3. Depress and hold AEC switch (31) then depress and hold washer switch (34). Character display (4) displays
[AC] in a flashing mode.
4. While still depressing AEC switch (31) and washer switch (34), depress alarm cancel switch (36) until
character display (4) stops flashing and changes to [ACP]. The automatic calibration mode is now started and
the governor actuator motor has moved to the initial high idle stop position. The governor actuator is now
calibrated to the factory engine rpm setting designated for position "10" of the engine speed dial switch.
5. Once character display (4) displays [ACt], the calibration procedure can be completed.
6. Depress AEC switch (31) and washer switch (34) in sequence until character display (4) displays [AC1]. The
calibration procedure for the factory engine rpm setting designated for positions "1" through "10" of the engine
speed dial switch is now started. The calibration procedure from this point takes approximately two minutes.
Character display (4) will change as follows:
NOTE: After initial setting has been completed, check to be sure that the governor lever is correctly positioned
(in contact with the high idle stopper) by rotating the pulley by hand.
* [AC1]
* [AC2]
* [AC3]
* [AC4]
* [AC5]
* [AC6]
* [AC7]
* [AC8]
* [AC0]
When [AC0] appears in character display (4), the calibration procedure is complete.
NOTE: If the data is not correct or within specified limits, character display (4) will indicate an error code as
shown in the following chart:
NOTE: If character display (4) displays [AC2] and [ -*] (*: error code shown in the following chart) alternately
during Automatic G/A Calibration procedure, it is an indication of the following possible problems. Have
necessary repairs made. If character display (4) displays [AC0] after taking corrective action, it indicates that the
automatic governor actuator calibration has been completed correctly.
NOTE: If the error code [- 1], [- 2], [- 3], [-15], or [-16] is indicated on character display (4), readjust the
accelerator/decelerator cables. See the section "Adjustment After Replacement Of Major Components".
NOTE: If the error code [- 4] through [-12] or [-14] is indicated on character display (4), check the
corresponding checking procedure in the section "Checking Procedures (Electronic Control System)".
NOTE: When character display (4) displays [-13], return all controls to the NEUTRAL position. If the problem
code still exists, check the pressure switches and circuits.
NOTE: Even if any of error code [-51], [-52], or [-53] appears after character display (4) has displayed [AC0],
the machine does not need to be stopped, but can continue to be operated. Since the three codes indicates that the
accelerator cable needs further adjustment, readjustment can be performed later using the following procedure.
a. If [-51] is displayed for two seconds, readjust the accelerator cable. See the section, "Adjustment After
Replacement Of Major Components".
b. If character display (4) alternates between [-52] and [ 10], every two seconds for example, decrease the
tension in the cable by loosening the adjusting nut of the accelerator cable by one turn. (If [ 15] is
indicated, then loosen the nut one and a half turns.)
do. Si la pantalla de caracteres (4) alterna entre [-53] y [10], por ejemplo, cada dos segundos, aumente la
tensión en el cable apretando la tuerca de ajuste del cable del acelerador una vuelta.
7. Detener " Modo de calibración"(a menos que se desee otra selección de función). Consulte la sección"
Calibración de la válvula reductora proporcional

NOTA: Este procedimiento de calibración se debe realizar cuando se reemplazó la válvula reductora
proporcional y / o el controlador. Este procedimiento se realiza en dos puntos de presión de cambio de potencia
2 2
de 5 kgf / cm [490 kPa (72 psi)] y 25 kgf / cm [2450 kPa (355 psi).
Compartimiento de la bomba principal

(40) Grifo de presión de cambio de potencia.
1. Detenga el motor e instale un manómetro de presión de 4900 kPa (700 psi) en el grifo de presión de cambio
de potencia (40).
2. Asegúrese de que el interruptor de respaldo de control de la bomba esté en la posición "AUT".
3. Inicie el " Modo de calibración". Consulte la sección" Arranque del modo de calibración ".
NOTA: El motor debe estar funcionando y debe tener una temperatura de aceite hidráulico de aproximadamente
50 ° C (122 ° F) para realizar este procedimiento de calibración.
4. Haga funcionar el motor con el selector de velocidad del motor en la posición "10".
NOTA: Activación de este modo de calibración.anula la función AEC. Si el interruptor de marcación rápida del
motor no está en la posición "10", la pantalla de caracteres (4) mostrará una "E" en la primera columna. La
velocidad del motor se debe corregir dentro de las especificaciones para continuar con el procedimiento de
calibración.
Panel de monitor electrónico (Calibración de la válvula reductora proporcional)

(4) Pantalla de caracteres. (27) Indicador de velocidad de viaje BAJA (tortuga). (28) Interruptor de control de velocidad de
desplazamiento. (31) Conmutador AEC. (34) Interruptor de la lavadora. (36) Interruptor de cancelación de alarma.
5. Presione el interruptor de control de velocidad de desplazamiento (28) hasta que se encienda el indicador
BAJA (tortuga) de velocidad de desplazamiento (27).
6. Character display (4) now displays [1 0]. The "1" indicates that the first calibration point has been accessed
and the "0" indicates that the middle step of the 19 individual calibration steps has been accessed. Each step will
change the power shift pressure by approximately 50 kPa (7.5 psi).
7. To change the power shift pressure:
a. To increase the power shift pressure, depress AEC switch (31) once. This will change character display
(4) to [1 1]. Each time AEC switch (31) is depressed, character display (4) increases by one until character
display (4) displays [1 9]. Also, the pressure reading at power shift pressure tap (40) increases by
approximately 50 kPa (7.5 psi) for each increase. The following is an example of character display (4)
readings in increasing order:
* [1-9]
* [1-8]
* [1-7]
* [1-6]
* [1-5]
* [1-4]
* [1-3]
* [1-2]
* [1-1]
* [1 0] = Middle Step
* [1 1]
* [1 2]
* [1 3]
* [1 4]
* [1 5]
* [1 6]
* [1 7]
* [1 8]
* [1 9]
b. To decrease the power shift pressure, depress washer switch (34) once to lower the value displayed in
character display (4). Each time washer switch (34) is depressed, character display (4) decreases by one in
descending order until character display (4) displays [1-9]. Also, the pressure reading at power shift
pressure tap (40) decreases by 50 kPa (7 psi) for each decrease. The following is an example of character
display (4) readings in decreasing order:
* [1 9]
* [1 8]
* [1 7]
* [1 6]
* [1 5]
* [1 4]
* [1 3]
* [1 2]
* [1 1]
* [1 0] = Middle Step
* [1-1]
* [1-2]
* [1-3]
* [1-4]
* [1-5]
* [1-6]
* [1-7]
* [1-8]
* [1-9]
8. To set "Calibration Point No. 1", perform the following steps:
a. Depress washer switch (34) until the pressure reading at tap (40) is less than 490 kPa (72 psi).
b. Depress AEC switch (31) until the pressure reading at tap (40) increases to approximately 490 kPa (72 psi).
NOTE: Pressure adjustments must always be made as the pressure is being increased.
c. Depress alarm cancel switch (36) to store the data in the controller.
d. Once the data is stored in the controller, display (4) changes to [2 0], which indicates that the first calibration
point has been accepted and the second calibration point can be performed. At this time, the character display
flashing light mode will change to a continuous lighting mode.
9. To set "Calibration Point No. 2", perform the following steps:
a. Depress washer switch (34) until the pressure reading at tap (40) is less than 2450 kPa (355 psi).
b. Depress AEC switch (31) until the pressure reading at tap (40) increases to approximately 2450 kPa (355 psi).
NOTE: Pressure adjustments must always be made as the pressure is being increased.
c. Depress alarm cancel switch (36) to store the data in the controller.
d. Once the data is stored in the controller, display (4) will change to [1 0], which indicates that the second
calibration point has been accepted and the controller has reset to the first calibration point.
10. Stop "Calibration Mode" (unless another function selection is desired). See the section, "Calibration Mode
Stop Procedure".
Calibration Mode Stop Procedure
Electronic Monitor Panel (Stopping Calibration Mode)

(4) Character display. (37) Service switch.
Use either of the following two methods:
1. Place engine in low idle position and turn the engine start switch to the OFF position.
2. Depress service switch (37) for a minimum of two seconds until character display (4) changes from
"Calibration Mode" to engine speed dial position.
Adjustment After Replacement Of Major

Components
When major components of the electronic control system have been replaced, adjustment is required.
The major components include:
* Governor actuator
* Proportional reducing valve
* Engine speed sensor
* Controller
Governor Actuator (Machines With Decelerator Cable)
Pump Compartment
(1) Accelerator cable. (2) Governor actuator. (3) Decelerator cable.
Engine Compartment
(4) Pulley. (5) Outer cable wire (decelerator). (6) Inner cable wire (accelerator).
Installation Of Accelerator And Decelerator Cables

(1) Accelerator cable. (3) Decelerator cable. (4) Pulley. (5) Outer cable wire (decelerator). (6) Inner cable wire (accelerator). (7) Slot. (8)
Locknut. (9) Support. (10) Nut. (11) Nut. (12) Locknut.
Initial Setting Of Governor Actuator

NOTE: This procedure is not necessary for a new governor actuator that is correctly calibrated for the initial
(factory) dial setting position "10".
1. Connect the harness of governor actuator (2) to the connector.
2. Determine the high idle position "10" (initial setting) by activating the automatic actuator calibration mode.
See the section in this module "Calibration Mode", Automatic Governor Actuator (G/A) Calibration"
Adjustment Of Accelerator Cable
1. Accelerator cable (1) is identified by its indentification seal. Turn nut (10) and locknut (8) of accelerator cable
(1) counterclockwise until they are as far apart as possible.
NOTE: If the identification seal is missing, accelerator cable (1) is the upper cable when viewed from the
governor actuator (2).
2. Place inner wire (6) into the inner groove (bottom groove, closest to the engine) of pulley (4).
3. Wrap inner wire (6) around (clockwise as viewed from the top of the machine) pulley (4).
4. Put the "T" end of inner wire (6) into slot (7). Make sure the "T" end of inner wire (6) is in line with the inner
groove (bottom groove, closest to the engine) after installation.
5. Put the threaded portion of accelerator cable (1) in the upper notch of support (9).
6. Turn pulley (4) counterclockwise (as viewed from the rear of the machine) to the high idle stop position (full
rotation position).
7. Hold pulley (4) against the high idle stop position and turn nut (10) clockwise until the slack is removed from
inner wire (6). Tighten nut (10) approximately an additional two turns by hand.
8. Torque (standard torque) locknut (8) against support (9).
Adjustment Of Decelerator Cable

1. Turn nut (11) and locknut (12) of decelerator cable (3) counterclockwise until they are as far apart as possible.
2. Place outer wire (5) into the outer groove (top groove, farthest from the engine) of pulley (4).
3. Wrap outer wire (5) around (counterclockwise as viewed from the top of the machine) pulley (4).
4. Put the "T" end of outer wire (5) into slot (7). Make certain the "T" end of outer wire (5) is in line with outer
groove (top groove, farthest from the engine) after installation.
5. Put the threaded portion of decelerator cable (3) in the upper notch of support (9). Make certain outer wire (5)
remains in outer groove of pulley (4).
6. Finger tighten nut (11) against support (9).
7. Loosen nut (11) approximately two turns to provide slack in outer wire (5).
8. Torque (standard torque) locknut (12) against support (9). Make certain nut (11) remains in position of
threaded portion of decelerator cable (3) and tighten locknut (12) against support (9).
9. Reinstall clamps to decelerator cable (3) and accelerator cable (1). Do not allow the cables to twist.
NOTE: Check to be sure that the governor lever is in contact with the high idle stop lever. Also make sure nuts
(11) and (10) are correctly tightened so that accelerator cable (1) is under tension and decelerator cable (3) has a
small amount of slack. Failure to do so could result in incorrect engine speed setting, or overload the governor
actuator. Governor actuator (2) must not be operated until the calibration procedure is complete. If actuator (2) is
operated before the calibration procedure is complete, recalibrate.
Calibration Of Governor Actuator
Reference: Make reference to the section in this module, "Calibration Mode", "Automatic Governor Actuator
Calibration".
1. Start the engine and perform the "Automatic Governor Actuator Calibration" by activating "Calibration Mode
Start-up".
2. After correctly calibrated, clear the error log information.
Reference: Make reference to the section in this module, "Calibration Mode", "Error Log".
Governor Actuator (Machines With Decelerator Cable) (2DL And

9KK Machines Only)
Pump Compartment
(1) Accelerator cable. (2) Governor actuator. (3) Decelerator cable.
Engine Compartment
(4) Pulley. (5) Outer cable wire (decelerator). (6) Inner cable wire (accelerator).
Installation Of Accelerator And Decelerator Cables

(1) Accelerator cable. (3) Decelerator cable. (4) Pulley. (5) Outer cable wire (decelerator). (6) Inner cable wire (accelerator). (7) Locknut.
(8) Nut. (9) Support. (10) Nut. (11) Slot. (12) Locknut.
Initial Setting Of Governor Actuator

NOTE: This procedure is not necessary for a new governor actuator that is correctly calibrated for the initial
(factory) dial setting position "10".
1. Connect the harness of governor actuator (2) to the connector.

2. Determine the high idle position "10" (initial setting) by activating the automatic actuator calibration mode.
See the section in this module "Calibration Mode", Automatic Governor Actuator (G/A) Calibration"

1. Accelerator cable (1) is identified by its identification seal. Turn nut (6) and locknut (8) of accelerator cable
(1) counterclockwise until they are as far apart as possible.
NOTE: If the identification seal is missing, accelerator cable (1) is the upper cable when viewed from the
governor actuator (2).
2. Place inner wire (6) into the inner groove (groove closest to the engine) of pulley (4).
3. Wrap inner wire (6) around (counterclockwise as viewed from the front of the machine) pulley (4).
4. Put the "T" end of inner wire (6) into slot (11). Make sure the "T" end of inner wire (6) is in line with the inner
groove (groove closest to the engine) after installation.
5. Put the threaded portion of accelerator cable (1) in the upper notch of support (9).
6. Turn pulley (4) clockwise (as viewed from the front of the machine) to the high idle stop position (full
rotation position).
7. Hold pulley (4) against the high idle stop position and turn nut (8) clockwise until the slack is removed from
inner wire (6). Tighten nut (8) approximately an additional two turns by hand.
8. Torque (standard torque) locknut (7) against support (9).
Adjustment Of Decelerator Cable
1. Turn nut (10) and locknut (12) of decelerator cable (3) counterclockwise until they are as far apart as possible.
2. Place outer wire (5) into the outer groove (groove farthest from the engine) of pulley (4).
3. Wrap outer wire (5) around (clockwise as viewed from the front of the machine) pulley (4).
4. Put the "T" end of outer wire (5) into slot (11). Make certain the "T" end of outer wire (5) is in line with outer
groove (groove farthest from the engine) after installation.
5. Put the threaded portion of decelerator cable (3) in the upper notch of support (9). Make certain outer wire (5)
remains in outer groove of pulley (4).
6. Finger tighten nut (10) against support (9).
7. Loosen nut (10) approximately two turns to provide slack in outer wire (5).
8. Torque (standard torque) locknut (12) against support (9). Make certain nut (10) remains in position of
threaded portion of decelerator cable (3) while tightening locknut (12) against support (9).
9. Reinstall clamps to decelerator cable (3) and accelerator cable (1). Do not allow the cables to twist.
NOTE: Check to be sure that the governor lever is in contact with the high idle stop lever. Also make sure nuts
(8) and (10) are correctly tightened so that accelerator cable (1) is under tension and decelerator cable (3) has a
small amount of slack. Failure to do so could result in incorrect engine speed setting, or overload the governor
actuator. Governor actuator (2) must not be operated until the calibration procedure is complete. If actuator (2) is
operated before the calibration procedure is complete, recalibrate.

Calibration".
Start-up".
Governor Actuator (Machines Without Decelerator Cable)
Controller Compartment (Behind Cab)(Typical)

(1) Governor actuator. (2) Accelerator cable.
Engine Compartment (Viewed From Top)(Typical)

(2) Accelerator cable. (3) Support. (4) Nut (5) Locknut. (6) Bellows. (7) Lever.
NOTE: An accelerator cable is a part of the governor actuator assembly. When installing a new governor
actuator and accelerator cable, the initial setting of the governor actuator is not necessary. However, if the
accelerator cable end position is changed from the factory setting by activating the engine speed dial, for
example, before the new governor actuator and accelerator cable are installed correctly, the governor actuator
needs to be calibrated to the initial (factory) engine rpm setting designated for dial position "10". If the current
accelerator cable was disconnected from the governor lever, the initial calibration procedure is required. See the
section in this module, "Calibration Mode, Automatic Governor Actuator Calibration".
1. Turn nut (4) and locknut (5) of accelerator cable (2) counterclockwise until they are as far apart as possible.
2. Put the threaded "L" end of accelerator cable (2) through the hole in lever (7) and install a nut to hold it in
position.
3. Put the other threaded portion of accelerator cable (2) in the notch of support (3).
4. Turn lever (7) counterclockwise (as viewed from the rear of the machine) to the high idle stop position (full
rotated position).
5. While holding lever (7) against the high idle stop, turn nut (4) clockwise until the slack is removed from
bellows (6). Tighten nit (4) approximately two additional turns.
6. Tighten locknut (5) against support (3). Make certain nut (4) remains in position of threaded portion of
accelerator cable (2) while tightening locknut (5) against support (3).
7. Reinstall two clamps to accelerator cable (2). Do not allow cable (2) to twist.
NOTE: Check to be sure that the governor lever is in contact with the high idle stopper. Also make sure nut (4)
is correctly tightened so that accelerator cable (2) is under correct tension. Failure to correctly tighten the cable
could result in incorrect engine speed setting or overload of the governor actuator.

Calibration".
Start-up".
Proportional Reducing Valve

1. Calibrate the proportional reducing valve.
Reference: See the section of this module, "Calibration Of Proportional Reducing Valve" in "Calibration
Mode".
2. After the proportional reducing valve is correctly calibrated, clear the error log information.
Referencia: vea la sección de este módulo, "Registro de errores" en el " Modo de calibración"".
Sensor de velocidad del motor (recogida magnética)
Instalación del sensor de velocidad del motor

(1) Sensor de velocidad. (2) Contratuerca. (3) Núcleo magnético. (4) Engranaje. (5) Alojamiento del volante.
DARSE CUENTA
El motor no debe estar funcionando antes de ajustar el sensor de
velocidad del motor.
1. Con el motor parado, apriete lentamente el sensor de velocidad (1) en el alojamiento del volante (5) hasta que
el núcleo magnético (3) esté en contacto con el engranaje (4).
2. Retroceda el sensor de velocidad 1/2 vuelta y apriete temporalmente la contratuerca (2).
3. Con el interruptor de marcación rápida del motor en la posición "1" (posición de Ralentí BAJO), arranque el
motor.
4. Inicie el programa de servicio "Modo de datos" y seleccione la función de visualización de velocidad del
motor.
Referencia: haga referencia a la sección en este módulo, "Modo de datos" - Velocidad del motor.
5. La pantalla de caracteres debe leer una velocidad de aproximadamente 800 rpm.
6. Si la pantalla de caracteres no lee las rpm correctas, apriete gradualmente el sensor de velocidad (1). No gire
más de 120 °.
7. Si es satisfactorio, pare el motor y apriete la contratuerca (2) a un par de 44 N · m (32 lb ft).
8. Una vez que la calibración del sensor de velocidad sea correcta, borre la información del registro de errores.
Referencia: consulte la sección de este módulo, "Registro de errores" en el " Modo de calibración"".
Sensor de velocidad del motor (captador magnético) (solo máquinas

2DL y 9KK)
Instalación del sensor de velocidad del motor

(1) Sensor de velocidad. (2) Contratuerca. (3) Núcleo magnético. (4) Engranaje. (5) Alojamiento del volante.
DARSE CUENTA
El motor no debe estar funcionando antes de ajustar el sensor de
velocidad del motor.
1. Con el motor parado, apriete lentamente el sensor de velocidad (1) en el alojamiento del volante (5) hasta que
el núcleo magnético (3) esté en contacto con el engranaje (4).
2. Retroceda el sensor de velocidad 3/4 de vuelta y apriete temporalmente la contratuerca (2).
3. Con el interruptor de marcación rápida del motor en la posición "1" (posición de Ralentí BAJO), arranque el
motor.
4. Inicie el programa de servicio "Modo de datos" y seleccione la función de visualización de velocidad del
motor.
Reference: Make reference to the section in this module, "Data Mode"-Engine Speed.
5. The character display should read a speed of approximately 800 rpm.
6. If the character display does not read correct rpm, gradually tighten speed sensor (1). Do not turn more than
120°.
7. If satisfactory, stop the engine and tighten locknut (2) to a torque of 44 N·m (32 lb ft).
8. After the speed sensor calibration is correct, clear the error log information.
Reference: See the section in this module, "Error Log" in "Calibration Mode".
Controller
1. Before removal/installation of the controller, be sure to turn the disconnect switch to the OFF position.
2. Perform the automatic governor calibration procedure.
Reference: See the section in this module, "Automatic Governor Actuator Calibration" in "Calibration Mode".
3. Perform the proportional reducing valve calibration procedure.
Reference: See the section in this module, "Calibration Of Proportional Reducing Valve" in "Calibration Mode".
Controller Input And Output Schematic (Voltage Signals In Normal

Operating Condition)
Controller Input And Output Schematic (Voltage Signals In Normal

Operating Condition) (2DL And 9KK Machines Only)
Terminal (Pin) Numbers Of Controller Connection And Voltage

Specifications
Voltage Specifications
Checking Procedures
Harness And Wire Identification
The colors and sizes of wires shown in the Electric Circuit Diagram are identified as described in the following
chart:
Example; [308] - BK - (18)
[308] = Circuit identification code.
BK = Wire color.
(18) = Wire size specified by AWG (American Wiring Gauge). If not indicated, wire size is AWG No. 16.
Electrical Components, Connectors, And Harness Location

This section includes information on how to use the separate "Electric Schematic" modules, Form No.
SENR6015, Form No. SENR6014, and Form No. SENR5459 to determine location of the electric components,
connectors, and harnesses.
The location charts are made up of electric components, connectors, and harnesses. The views contain general
views and area views. Area views include the following:
* Area A: Cab
* Area B: Right console
* Area C: Left console
* Area D: Relay panel
* Area E: Main control valve compartment
Below is a guide to read components and harness/connector location charts.
* Component location chart:
The component location chart uses white circles as location labels in the general and area views.
Alphabetical letters in the connector and vehicle location column indicate location in the area views.
* Harness and connector location chart:
The harness and connector location charts use black circles as location labels in the general and area
views. Alphabetical letters in the connector and vehicle location column indicate the area views where
they are located. the "*" indicates that it is connected to the component in its harness and/or components
column.
NOTE: Harnesses in partial electric schematics given in the "Checking Procedures" are identified by A, B, and
C, which are also indicated in the general and area views.
NOTE: The material in this module is intended to be used with one of the separate "Electrical Schematic"
modules, Form No. SENR6015, Form No. SENR6014, or Form No. SENR5459.
Checking Procedures (Electronic Control System)

Introduction
Problem Description
The problem description indicates problems represented by the character display on the monitor panel.
Solution
The solution provides two types of information;
* Connector check provides information on the connectors that have to be checked before troubleshooting
using the checking procedure chart. Check the connectors specified for improper connections. A loose
contact between two connectors can be caused by water in the connectors. Check the connectors before
troubleshooting.
* Checking procedure chart provides information on troubleshooting problems indicated by the error code
on the character display on the monitor panel.
Example Chart
Electronic Control System Checking Procedure Chart

(1) Preparations. (2) Problem description. (3) Error code on character display (Ch.D.). (4) Check items. (5) Probable causes. (6) Solution.
NOTE: The character display on the monitor panel indicates error code on character display (3) assigned for the
real time errors and error log, if problem(s) occurs. The charts that follow should be used to troubleshoot
problems indicated by error code on character display (3).
Preparations (1) provide information on the preliminary arrangements that must be made before troubleshooting.
Problem description (2) indicates problems shown by the character display on the monitor panel.
Error code on character display (3) indicates specific codes for real time errors and error log. Service Program
selection determines the pattern of the character display.
Check items (4) list items that must be checked with a multimeter.
a. In the check items (4), "0Ohms" means "there is continuity", whereas "infinite Delta " means that "there
is no continuity".
b. Connector check - [other than()]: 0Ohms.
NOTE: [other than()] means all the terminals and pins except the one specified in ().
The following is an explanation of the terms in "Check items (4)":
Example; (1) - (2) of CONN46M
(1) = Pin number.
- = Short circuit indication.
CONN46 = Connector number.
M = The male (M) or female (F) half of the connector.
Probable causes (5) shows probable cause(s) of a problem.
Solution (6) shows the corrective action that should be taken to solve a particular problem. The statement
"Replace" includes "Repair if possible".
When a continuity check is to be performed, "turn the starter switch to the OFF position". This stops the power
supply to prevent damage to the tester or short-circuiting the power supply.
When a voltage check is to be made, "turn the starter switch to the ON position" to allow power supply. The
engine should be in operation unless otherwise specified. Stable inputs and outputs of controller cannot be
obtained without the engine running.
NOTICE
To avoid damage to electrical components when the power supply is
ON, make sure disconnected connectors and wires do not come in
contact with the machine.
[Elec #1] Controller Self-Diagnostic LED Display
Controller Compartment
(1) LED lamp. (2) Controller.
[Elec #1-1] Normal

Normal: Green LED lamp (1) comes ON.
[Elec #1-2] Yellow And Green LED Lamp ON

Problem:
Problem in communication line between controller and monitor causes the yellow and green LED lamps to come
ON.
Solution:
Check problem according to [Elec #10-1] and [Elec #10-2].
[Elec #1-3] Green And Red LED Lamp ON
Problem:
Problem in controller causes the green LED lamp to come ON in continuous lighting mode and red LED lamp to
come ON in continuous lighting mode or flashing mode. In some cases, yellow LED lamp may come ON.
Solution:
Replace the controller.
[Elec #1-4] No Power To Controller And LED Lamps ON

Problem:
No power supply to controller causing LED lamp (1) to not come ON.
Solution:
Check problem according to [Elec #1-5].
[Elec #1-5] No Power To Controller
Problem:
No power supply to controller.
Solution:
Check to ensure that CONN1, 3, and 24 are properly connected. If the problem still exists, troubleshoot
according to the following checking procedure chart.
Partial Electric Schematic
Partial Electric Schematic (2DL And 9KK Machines Only)
[Elec #2-1] PRV Circuit Is Open

Problem:
Proportional reducing valve circuit is open.
Solution:
Check to ensure that CONN56, 8, 1, and 17 are properly connected. If the problem still exists, troubleshoot
[Elec #2-2] PRV Circuit Is Shorted To Body Ground

Problem:
Proportional reducing valve circuit is shorted to body ground.
Solution:
Check to ensure that CONN56, 8, 1, and 17 are properly connected. If problem still exists, troubleshoot
[Elec # 2-3] El circuito PRV está en cortocircuito al voltaje de la batería

Problema:
El circuito de la válvula reductora proporcional está cortocircuitado al voltaje de la batería.
Solución:
Asegúrese de que CONN56, 8, 1 y 17 estén conectados correctamente. Si el problema persiste, resuelva el

problema de acuerdo con el siguiente cuadro de procedimientos de verificación.
[Elec # 3A] El sensor de velocidad del motor está abierto o no está instalado correctamente
Problema:
El circuito del sensor de velocidad del motor (captador magnético) está abierto o el sensor de velocidad no está
instalado correctamente (problema de velocidad del motor).
Solución:
Compruebe para asegurarse de que CONN42, 60, 9 y 2 estén conectados correctamente. Si el problema persiste,
resuelva el problema de acuerdo con el siguiente cuadro de procedimientos de verificación.
[Elec # 3B] El sensor de velocidad del motor está abierto o no está instalado correctamente
(solo máquinas 2DL y 9KK)
Problema:
El circuito del sensor de velocidad del motor (captador magnético) está abierto o el sensor de velocidad no está
instalado correctamente (problema de velocidad del motor).
Solución:
Asegúrese de que CONN42, 9 y 2 estén bien conectados. Si el problema persiste, resuelva el problema de
acuerdo con el siguiente cuadro de procedimientos de verificación.
[Elec # 4-1A] El circuito del interruptor de presión de viaje está abierto o en corto a la
masa del cuerpo
Problema:
El circuito del interruptor de presión de viaje está abierto o en cortocircuito a masa del cuerpo.
Solución:
Asegúrese de que CONN51, 10 y 2 estén correctamente conectados. Compruebe que el orificio en el paso de la
señal al interruptor de presión no esté bloqueado. Si el problema persiste, resuelva el problema de acuerdo con el
siguiente cuadro de procedimientos de verificación.
[Elec # 4-1B] El circuito del interruptor de presión de viaje está abierto o en corto a la
masa del cuerpo (solo máquinas 2DL y 9KK)
Problema:
El circuito del interruptor de presión de viaje está abierto o en cortocircuito a masa del cuerpo.
Solución:
[Elec # 4-2A] El circuito del interruptor de presión del implemento / oscilación está abierto
o en corto a la masa del cuerpo
Problema:
El circuito del interruptor de presión del implemento / giro está abierto o en cortocircuito a masa del cuerpo.
Solución:
[Elec # 4-2B] El circuito del interruptor de presión del implemento / oscilación está abierto
o en cortocircuito a masa del cuerpo (solo máquinas 2DL y 9KK)
Problema:
El circuito del interruptor de presión del implemento / giro está abierto o en cortocircuito a masa del cuerpo.
Solución:
[Elec # 4-3] El circuito del interruptor de presión de elevación de la pluma está abierto o
en corto a masa del cuerpo
Problema:
El circuito del interruptor de presión de elevación de la pluma está abierto o en cortocircuito a masa del cuerpo.
Solución:
Asegúrese de que los CONN50, 10 y 2 estén correctamente conectados. Compruebe que el orificio en el paso de
la señal al interruptor de presión no esté bloqueado. Si el problema persiste, resuelva el problema de acuerdo con
el siguiente cuadro de procedimientos de verificación.
[Elec # 5] El controlador recibe una señal de velocidad del motor diferente a la

especificada "10"
Problema:
El controlador recibe una señal de velocidad del motor diferente a la especificada "10" del dial de velocidad del
motor.
Solución:
Asegúrese de que CONN27, 24 y 1 estén correctamente conectados. Si el problema persiste, resuelva el

[Elec # 6-1] El circuito del sensor de realimentación del accionador del regulador está
abierto o en cortocircuito al voltaje de la batería
Problema:
El circuito del sensor de realimentación del accionador del regulador está abierto o en cortocircuito a la tensión
de la batería.
Solución:
[Elec #6-2] Governor Actuator Feedback Sensor Circuit Is Shorted To Body Ground
Problem:
Governor actuator feedback sensor circuit is shorted to body ground.
Solution:
Check to ensure that CONN44, 3, and 2 are properly connected. If the problem still exits, troubleshoot according
to the following checking procedure chart.
[Elec #6-3] Governor Actuator Motor Circuit Is Shorted To Body Ground.

Problem:
Governor actuator motor circuit is shorted to body ground.
Solution:
[Elec # 6-4] El motor del actuador del gobernador no gira o el circuito del motor del
actuador del gobernador está en cortocircuito al voltaje de la batería
Problema:
El motor del accionador del regulador no gira o el circuito del motor del accionador del regulador está
cortocircuitado al voltaje de la batería.
Solución:
Verifique para asegurarse de que CONN44, 3, 1 y 18, y los circuitos del interruptor de cambio de velocidad y el
interruptor de respaldo del gobernador estén conectados correctamente. Si el problema persiste, resuelva el
[Elec # 6-5] El circuito del motor del actuador del regulador está abierto o el interruptor
de respaldo del regulador está en la posición "MAN".
Problema:
El circuito del motor del actuador del regulador está abierto o el interruptor de respaldo del regulador está en la
posición "MAN".
Solución:
Asegúrese de que CONN44, 3, 1 y 18 estén correctamente conectados. Si el problema persiste, resuelva el

[Elec #6-6] Governor Actuator Remains Deactivated An Elapse Time Of 2.5 Seconds After
Engine Speed Dial Setting
Problem:
Governor actuator remains deactivated an elapse time of 2.5 seconds after engine speed dial has been activated.
Solution:
Troubleshoot according to the following checking procedure chart.
Partial Electrical Schematic
Partial Electrical Schematic (2DL And 9KK Machines Only)
[Elec #7A] Low Idle Switch Circuit Is Open Or Shorted To Body Ground
Problem:
Low idle switch circuit is open or shorted to body ground.
Solution:
Check to ensure that CONN28, 25 and 1 are properly connected. If the problem still exists, troubleshoot
[Elec #7B] Low Idle Switch Circuit Is Open Or Shorted To Body Ground (2DL And 9KK
Machines Only)
Problem:
Low idle switch circuit is open or shorted to body ground.
Solution:

[Elec # 8-1] El circuito de retorno de la válvula solenoide fina está cortocircuitado al

voltaje de la batería
Problema:
El circuito de retorno de la válvula solenoide fina está cortocircuitado al voltaje de la batería.
Solución:
Asegúrese de que CONN53, 10 y 2 estén correctamente conectados. Si el problema persiste incluso con las
conexiones correctas, resuelva el problema de acuerdo con el siguiente cuadro de procedimientos de
verificación.
[Elec # 8-2] El cable de voltaje de la batería del circuito de la válvula solenoide de control
fino está en corto a masa del cuerpo
Problema:
El cable de voltaje de la batería del circuito de la válvula solenoide de control fino está cortocircuitado a masa
del cuerpo.
Solución:
Check to ensure that CONN53, 10, 4, and 2 are properly connected. If the problem still exists even with the
correct connections, troubleshoot according to the following checking procedure chart.
[Elec #8-3] Fine Control Solenoid Valve Circuit Is Open

Problem:
Fine control solenoid valve circuit is open.
Solution:
Check to ensure that CONN53, 10, 4, and 2 are properly connected. If the problem still exists even with the
correct connections, troubleshoot according to the following checking procedure chart.
[Elec #8-4] Swing Priority Solenoid Return Circuit Is Shorted To Battery Voltage
Problem:
Swing priority solenoid return circuit is shorted to battery voltage.
Solution:
Check to ensure that CONN54, 10, and 2 are properly connected. If the problem still exists even with the correct
connections, troubleshoot according to the following checking procedure chart.
[Elec #8-5] Battery Voltage Cable Of Swing Priority Solenoid Valve Circuit Is Shorted To
Body Ground
Problem:
Battery voltage cable of swing priority solenoid valve circuit is shorted to body ground.
Solution:
Verifique para asegurarse de que CONN54, 10, 4 y 2 estén correctamente conectados. Si el problema persiste
incluso con las conexiones correctas, resuelva el problema de acuerdo con el siguiente cuadro de procedimientos
de verificación.
[Elec # 8-6] El circuito de la válvula solenoide de prioridad de giro está abierto

Problema:
El circuito de la válvula solenoide de prioridad de giro está abierto.
Solución:
Verifique para asegurarse de que CONN54, 10, 4 y 2 estén correctamente conectados. Si el problema persiste
incluso con las conexiones correctas, resuelva el problema de acuerdo con el siguiente cuadro de procedimientos
de verificación.
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[Elec # 9-1] El circuito de retorno de la válvula solenoide de velocidad de desplazamiento

está en corto al voltaje de la batería
Problema:
El circuito de retorno de la válvula solenoide de velocidad de desplazamiento está cortocircuitado al voltaje de la

batería.
Solución:

[Elec # 9-2] El cable de voltaje de la batería del circuito de la válvula solenoide de la

velocidad de desplazamiento está cortocircuitado a masa del cuerpo
Problema:
El cable de voltaje de la batería del circuito de la válvula solenoide de velocidad de recorrido está
cortocircuitado a masa del cuerpo.
Solución:

[Elec # 9-3] El circuito de la válvula solenoide de velocidad de desplazamiento está abierto

Problema:
El circuito de la válvula solenoide de velocidad de desplazamiento está abierto.
Solución:

[Elec # 10-1A] No hay fuente de alimentación para monitorear

Problema:
No hay fuente de alimentación para monitorear.
Solución:

[Elec # 10-1B] No hay fuente de alimentación para monitorear (solo máquinas 2DL y
9KK)
Problema:
No hay fuente de alimentación para monitorear.

Solución:

[Elec # 10-2] La línea de comunicación entre el controlador y el monitor es anormal

Problema:
La línea de comunicación entre el controlador y el monitor es anormal.
Solución:
[Elec #11-1] Chassis Light System Problem
Problem:
Chassis light system problem.
Solution:
Check to ensure that CONN4, 3, and 1 are properly connected. If the problem still exists, troubleshoot according
to the following sequence chart.
[Elec #11-2] Chassis Light Return Circuit Is Shorted To Battery Voltage
Problem:
Chassis light return circuit is shorted to battery voltage.
Solution:
Check to ensure that CONN3 and 1 are properly connected. If the problem still exists, troubleshoot according to
the following sequence chart.
[Elec #11-3] Boom Light System Problem

Problem:
Boom light system problem.
Solution:
according to the following sequence chart.
[Elec #11-4] Boom Light Return Circuit Is Shorted To Battery Voltage

Problem:
Boom light return circuit is shorted to battery voltage.
Solution:
[Elec #12-1A] Wiper System Problem

Problem:
Wiper system problem.
Solution:
Check to ensure that CONN32, 34, 13, 6, 3, and 1 are properly connected. If the problem still exists,
troubleshoot according to the following sequence chart.
[Elec #12-1B] Wiper System Problem (2DL And 9KK Machines Only)
Problem:
Wiper system problem.
Solution:
Check to ensure that CONN32, 28, 13, 6, 3, and 1 are properly connected. If the problem still exists,
troubleshoot according to the following sequence chart.
[Elec #12-2] Wiper Return Circuit Is Shorted To Battery Voltage
Problem:
Wiper return circuit is shorted to battery voltage.
Solution:
[Elec #12-3] Washer System Problem

Problem:
Washer system problem.
Solution:
Check to ensure that CONN3, 4, and 1 are properly connected. If the problem still exists, troubleshoot according
[Elec #12-4] Washer Return Circuit Is Shorted To Battery Voltage

Problem:
Washer return circuit is shorted to battery voltage.
Solution:
[Elec #13A] Engine Oil Pressure Switch Circuit Is Open

Problem:
Engine oil pressure switch circuit is open.
Solution:
[Elec #13B] Engine Oil Pressure Switch Circuit Is Open (2DL And 9KK Machines Only)
Problem:
Engine oil pressure switch circuit is open.
Solution:
[Elec #14-1] Action Alarm Buzzer Circuit Is Open

Problem:
Action alarm buzzer circuit is open.
Solution:
[Elec #14-2] Action Alarm Buzzer Circuit Is Shorted To Body Ground

Problem:
Action alarm buzzer circuit is shorted to body ground.
Solution:
[Elec #14-3] Action Alarm Buzzer Return Circuit Is Shorted To Battery Voltage
Problem:
Action alarm buzzer return circuit is shorted to battery voltage.
Solution:
[Elec #15-1] Engine Coolant Temperature Sensor Circuit Is Open Or Shorted To Battery
Voltage
Problem:
Engine coolant temperature sensor circuit is open or shorted to battery voltage.
Solution:
[Elec #15-2] Engine Coolant Temperature Sensor Circuit Is Shorted To Body Ground
Problem:
Engine coolant temperature sensor circuit is shorted to body ground.
Solution:
[Elec #16-1] Hydraulic Oil Temperature Sensor Circuit Is Open Or Shorted To Battery
Voltage
Problem:
Hydraulic oil temperature sensor circuit is open or shorted to battery voltage.
Solution:
[Elec #16-2] Hydraulic Oil Temperature Sensor Circuit Is Shorted To Body Ground
Problem:
Hydraulic oil temperature sensor circuit is shorted to body ground.
Solution:
[Elec #17-1] Fuel Level Sensor Circuit Is Open Or Shorted To Battery Voltage
Problem:
Fuel level sensor circuit is open or shorted to battery voltage.
Solution:
[Elec #17-2] Fuel Level Sensor Circuit Is Shorted To Body Ground
Problem:
Fuel level sensor circuit is shorted to body ground.
Solution:
Partial Electrical Schematic
Partial Electrical Schematic (2DL And 9KK Machines Only)
[Elec #18-1] Battery Voltage Is Abnormal

Problem:
Battery voltage is abnormal (not within 23 to 32V).
Solution:
Check to ensure that CONN24, 11, 9, 5, 2, and 1, and terminals of alternator, breaker and terminal block are
properly connected. If the problem still exists, troubleshoot according to the following sequence chart.
[Elec #18-2A] Alternator Terminal W Circuit Is Open

Problem:
Alternator terminal W circuit is open.
Solution:
Check to ensure that CONN9, 2, and terminal W are properly connected. If the problem still exists, troubleshoot
[Elec #18-2B] Alternator Terminal P Circuit Is Open (2DL And 9KK Machines Only)
Problem:
Alternator terminal P circuit is open.
Solution:
Check to ensure that CONN9, 2, and terminal P are properly connected. If the problem still exists, troubleshoot
[Elec #19] Diagnosis Of Backup Switches And Starter Switch.

Disconnect all harnesses from backup switches and starter switch. Check for continuity across terminals of each
of the above switches. Any results other than given below indicate that the switch has loose contacts.
[Elec #19-1] Pump Backup Switch
[Elec #19-2] Governor Backup Switch
[Elec #19-3] Engine Speed Change Switch
[Elec #19-4A] Starter Switch
[Elec #19-4B] Starter Switch (2DL And 9KK Machines Only)
[Elec #20] Heater Signal Is Shorted To Battery Voltage (2DL And 9KK Machines Only)
Problem:
Heater signal is shorted to battery voltage.
Solution:
Check to ensure that CONN1 and 3, and terminals of heater relay, terminal block and air heater are properly
connected. If the problem still exists, troubleshoot according to the following sequence chart.
[Elec #21] Governor Actuator Feedback Sensor Voltage Is Too Low Or Not Stable
Problem:
Governor actuator feedback sensor voltage is too low ([E 9]) or not stable ([E12]).
Solution:
With the AEC switch in the OFF position, place the engine speed dial at position "10". Check to see if the
voltage between terminal 21 of controller connector B and ground is 6.3 to 6.7 V. If the voltage is within 6.3 to
6.7, it is normal. If not, check or replace the governor actuator, as necessary.
NOTE: To check voltages, see in this module, "Controller Connector Terminal Voltage".
[Elec #22] Engine Coolant Temperature Is Too High
Problem:
Engine coolant temperature is too high.
Solution:
Troubleshoot according to the following sequence chart.
[Elec #23] Engine Oil Pressure Is Too Low

Problem:
Engine oil pressure is too low.
Solution:
[Elec #24] Hydraulic Oil Temperature Is Too High
Problem:
Hydraulic oil temperature is too high.
Solution:
[Elec #25] There Is More Than 100 rpm Difference Between Engine Speed Dial Setting
And Actual Speed
Problem:
There is more than 100 rpm difference between engine speed dial setting (speed calculated from governor
actuator feedback signal) and actual speed.
Solution:
[Elec #26] Monitor Takes At Least One Second To Respond To Controller's Signal
Problem:
Monitor takes at least one second to respond to controller's signal.
Solution:
[Elec #27] Monitor RAM Is Not Normal
Problem:
Monitor RAM (Random Access Memory) is not normal.
Solution:
[Elec #28] Controller Is Informed Of Its Error Signal By Monitor
Problem:
Controller is informed of its error signal by monitor.
Solution:
[Elec #29] Controller Detects Its Error Signal By Itself
Problem:
Controller detects its error signal by itself.
Solution:
[Elec #30] Error In Controller Memory

Problem:
Error in controller memory.
Solution:
[Elec #31A] A Controller For A Different Machine Is Installed Or Harness Code Problem
Problem:
A controller for a different machine is installed or harness code problem.
Solution:
Check to ensure that CONN1 and 58 are properly connected. If the problem still exists, troubleshoot according
[Elec #31B] A Controller For A Different Machine Is Installed Or Harness Code Problem
(2DL And 9KK Machines Only)
Problem:
A controller for a different machine is installed or harness code problem.
Solution:
Check to ensure that CONN1 and 58 are properly connected. If the problem still exists, troubleshoot according
[Elec #32] Engine Stalls

Problem:
Engine stalls.
Solution:
Checking Procedures (Hydraulic System)

(Hyd #1) Hydraulic Oil Supply
Reference: Refer to the section, "Hydraulic Oil Tank" in the "Operation and Maintenance Manual".
(Hyd #2) Suction Filter Clean Up

Reference: Refer to the section, "Service Screen And Filters" in the "Operation and Maintenance Manual", for
filter cleaning procedures.
(Hyd #3) Adjustment Of Pressure And Flow
Reference: See the section in this module, "Hydraulic System Testing And Adjusting".
(Hyd #3-1) Check And Adjustment Of Main Relief Valve Pressure

(Hyd #3-2) Check And Adjustment Of Line Relief Valve Pressure
(Hyd #3-3) Check And Adjustment Of Swing Relief Valve Pressure
(Hyd #3-4) Check And Adjustment Of Travel Crossover Relief Valve Pressure
(Hyd #3-5) Check And Adjustment Of Pilot Relief Valve Pressure
(Hyd #3-6) Adjustment Of Main Pump Flow
(Hyd #4) Check Of Pilot Pressure At Main Control Valve Inlet
Main Control Valve Compartment (Viewed From Machine Rear)

(1) Pilot line (boom RAISE). (2) Pilot line (bucket CLOSE). (3) Pilot line (REVERSE RIGHT travel). (4) Pilot line (REVERSE LEFT
travel). (5) Pilot line (swing LEFT). (6) Pilot line (stick IN).
Main Control Valves (Viewed From The Front Of The Machine)

(7) Pilot line (boom LOWER). (8) Pilot line (bucket OPEN). (9) Pilot line (FORWARD RIGHT travel). (10) Pilot line (FORWARD LEFT
travel). (11) Pilot line (swing RIGHT). (12) Pilot line (stick OUT).
1. To check the pilot pressure at each inlet port of the main control valves, connect a tee between each pilot line
and its control valve.
2. Attach a 4900 kPa (700 psi) pressure gauge to the tee.
3. With the hydraulic activation control lever in the UNLOCKED position, operate the pilot control lever for
each function.
(Hyd #5) Swing Motor Performance Problem (Measurement Of Case Drain Oil)(Machines
With Swing Lock Pin)
Swing Motor Compartment

(1) Case drain hose. (2) Tee. (3) Case drain hose.
To check the swing motor performance, measure the amount of swing motor case drain oil as follows:
1. Disconnect case drain hose (3) from tee (2) on the swing motor.
2. Install a plug in the end of case drain hose (3) and a cap in the open end of tee (2).
3. Disconnect case drain hose (1) from the swivel.
4. Install a cap in the open port of the swivel.
5. Put the open end of case drain hose (1) into a suitable measuring container.
6. With the swing pin in the LOCKED position, operate the swing control for one minute.
7. Measure the amount of swing motor case drain oil.
NOTE: The maximum acceptable case drain oil with a swing relief pressure setting of 24 000 ± 490 kPa (3500
± 72 psi) must be:
For a New swing motor ... 20 liter/min (5.3 U.S. gpm)
For a Rebuilt swing motor ... 23 liter/min (6.1 U.S. gpm)
(Hyd #5) Swing Motor Performance Problem (Measurement Of Case Drain Oil)(Machines
Without Swing Lock Pin)

(1) Case drain hose. (2) Tee. (3) Case drain hose.
In Front Of Main Control Valves

(4) Elbow. (5) Pilot line. (6) Cap.
To check the swing motor performance, measure the amount of swing motor case drain oil as follows:
1. Stop the engine. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".
2. Disconnect case drain hose (3) from tee (2) on the swing motor.
3. Install a plug (3/4-16UN) in the end of case drain hose (3) and a cap (3/4-16UN) in the open end of tee (2).
4. Disconnect case drain hose (1) from the swivel. Put the open end of case drain hose (1) into a suitable
measuring container.
5. Install a cap (3/4-16UN) in the open port of the swivel.
6. Engage the swing parking brake as follows;
a. Disconnect pilot line (5) from elbow (4).
b. Install a cap (9/16-18HD)(6) on elbow (4). Leave the end of pilot line (5) open to the air.
7. Start and run the engine at no-load high idle speed of 1860 ± 50 rpm with the power mode selector switch at
Mode III position.
8. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).
9. Operate the swing control for one minute. Measure the amount of swing motor case drain oil and record the
measurement.
NOTE: Check to be sure that the swing parking brake is correctly being engaged while the swing control is
activated.
10. Release the swing parking brake as follows:
a. Stop the engine and release the pressure in the hydraulic system. See the section, "Release Of Pressure In The
Hydraulic System".
b. Remove cap (9/16-18HD)(8S4950)(6) from elbow (4).
c. Connect pilot hose (5) to elbow (4).
11. Operate the swing control to place the swing motor barrel in a new position.
12. Repeat Steps 1 through 9. Take three measurements.
NOTE: The maximum acceptable case drain oil with a swing relief pressure setting of 24 000 ± 490 kPa (3500
± 72 psi) must be:
For a New swing motor ... 20 liter/min (5.3 U.S. gpm)
For a Rebuilt swing motor ... 23 liter/min (6.1 U.S. gpm)
(Hyd #6) Travel Motor Performance Problem (Measurement Of Case Drain)
Travel Motor
(1) Connector. (2) Drain hose.
To check the travel motor performance, measure the amount of case drain oil as follows:
1. Disconnect drain hose (2) from connector (1). Install a plug in the open end of drain hose (2).
2. Connect one end of the vinyl hose to connector (1) and put the other end of the vinyl hose into a suitable
measuring container.
3. With the track blocked, operate the travel control for one minute.
4. Measure the amount of case drain oil.
5. Remove the track block, and move the machine forward to place the travel motor barrel in a new position.
6. Repeat steps 1 through 4.
NOTE: The maximum acceptable case drain oil at each measuring point with a main relief pressure of 34 300 ±
490 kPa (4950 ± 72 psi) must be:
For a New travel motor ... 15 liter/min (4.0 U.S. gpm)
For a Rebuilt travel motor ... 18 liter/min (4.8 U.S. gpm)
Testing And Adjusting

Introduction
Machines With Swing Lock Pin
Hydraulic oil pressure can remain in the hydraulic systems on this

machine after the engine and pump have been stopped. Serious injury
can be caused if this pressure is not released before any service is done
on the hydraulic systems. To prevent possible injury, refer to section,
Release Of Pressure In The Hydraulic System, before any fitting, hose
or component is loosened, tightened, removed or adjusted.
When possible, the bucket must always be lowered to the ground before
service is started. When it is necessary for the boom to be in the raised
position while tests or adjustments are done, be sure that boom, stick
and bucket have correct support.
Swing lock must be engaged before service is started.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
During diagnosis of the hydraulic system, remember that correct oil temperature, flow, and pressure are
necessary for correct operation. Pump output (oil flow) is a function of engine speed (rpm). Oil pressure is
caused by resistance to the flow of oil.
Machines Without Swing Lock Pin
Hydraulic oil pressure can remain in the hydraulic systems on this

machine after the engine and pump have been stopped. Serious injury
can be caused if this pressure is not released before any service is done
on the hydraulic systems. To prevent possible injury, refer to section,

Release Of Pressure In The Hydraulic System, before any fitting, hose
or component is loosened, tightened, removed or adjusted.
When possible, the bucket must always be lowered to the ground before
service is started. When it is necessary for the boom to be in the raised
position while tests or adjustments are done, be sure that boom, stick
and bucket have correct support.
Always move the machine to a location away from the travel of other
machines. Be sure that other personnel are not near the machine when
the engine is running and tests or adjustments are being made.
During diagnosis of the hydraulic system, remember that correct oil temperature, flow, and pressure are
necessary for correct operation. Pump output (oil flow) is a function of engine speed (rpm). Oil pressure is
caused by resistance to the flow of oil.
Visual Checks
A visual inspection of the system is the first step when troubleshooting a problem. Make the inspection with the
engine off and the implements lowered to the ground.
1. Check the level of the oil in the hydraulic tank. Slowly loosen the hydraulic tank air vent plug and release the
pressure before the filler cap is removed.
2. Remove the filter element and check it for material that would give an indication of damage to a component.
3. Inspect all lines and connections for damage or leaks.
4. Inspect control linkage for bent, broken, or damaged components.
Checks During Operation

The checks during operation can be used to find leakage in the system. They can also be used to find a valve,
pump, motor, or cylinder that is not working correctly. The speed of rod movement or the torque on a motor can
be used to check the condition of the cylinders, motors, and pumps.
Operational Tests
NOTE: For specifications given in "Operational Tests", a "NEW" specification is the performance that can be
expected for a new machine. A "REBUILD" specification is the performance target to use after rebuilding the
components of a system. A machine that performs beyond "SERVICE LIMIT" specifications should be checked
for improper maintenance or adjustment, component wear, or failure.
Specifications given in charts for a machine equipped with 5700 mm (18 ft 8 in) boom, 2900 mm (9 ft 6 in)
stick, and SAE 0.82 m3 (1 yd3) bucket.
NOTE: The power mode selector switch must be placed at Mode III position, unless otherwise specified, during
tests.
Operational Test Preparations
1. Engine speed:
Excavator with no load at high idle, 1860 ± 50 rpm
2. Hydraulic oil temperature: 55 ± 5°C (130 ± 9°F)
NOTE: Fully move the stick in and out several times until the normal hydraulic oil temperature is reached.
3. Relief valve pressure settings are set according to specification.
Reference: Make reference to the section in this module "Relief Valves", "Specifications".
Travel Test On Level Ground
Test Preparation:
1. Set engine speed and increase the hydraulic oil to normal operating temperature.
Reference: Make reference to the section "Operation Tests Preparation"
2. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft) long.
3. Draw a 25 m (82.5 ft) straight line on travel test ground as a reference line.
4. Position the machine so that one track is in line (parallel) with the reference line. Put the machine in the travel
test position as shown in the illustration.
5. The bucket must be empty.
Test Procedure:
1. Start the engine and place the power mode selector switch in mode III position. Place the engine speed dial at
position "10" and the travel speed switch in HIGH (rabbit) position. Move the machine by operating both travel
levers at the same time.
2. The first 5 m (16.5 ft) are for a preliminary run. Measure the time required for the machine to travel the
remaining 20 m (66 ft) in each direction (FORWARD and REVERSE).
3. Measure the travel deviation from the reference line.
4. Repeat the above procedure with the travel speed switch in LOW (turtle) position.
NOTE: The following chart represents the time (in seconds) it should take to complete the 20 m (66 ft) test run:
NOTE: The following chart represents the travel deviation from the reference line:
Travel On Level Ground (Optional Test)

NOTE: If suitable ground (as stated in Step No. 2 in "Test Preparation" for "Travel On Level Ground") cannot
be found, the following test should be done as a substitute.
Test Preparation:
2. Place the machine on level ground.
3. Raise a track for the test as shown in the illustration.
4. Put a mark on a shoe of the raised track.
Test Procedure:
1. Start the engine and place the power mode selector switch in power Mode III position. Run the raised track
with the engine speed dial at position "10" (high idle) and the travel speed switch in HIGH (rabbit) position.
2. Measure the time required for the track to make three complete turns (revolutions) in each direction
(FORWARD and REVERSE).
3. Repeat the above procedure with the travel speed switch in LOW (turtle) position.
Drift On Slope
Measuring the amount of drift of the machine on a slope will determine if there is a need to check the travel
brake.
Test Preparation:
1. Place the machine on a slope of 12°. The slope surface must be hard and smooth.
2. Put the implements in the position shown in the illustration.
3. Bucket should be empty.
Test Procedure:
1. Put marks on both track and ground to indicate its relative position to the slope.
2. Stop the engine and time three minutes (using a stopwatch).
3. Measure (with a scale) the distance the tracks have moved on the slope.
Swing Speed And Over Swing (On Level Ground)
Measuring the swing speed and over swing of the machine will determine if there is a need to check the swing
motor and/or anti-reaction valve.
Test Preparation:
2. Place the machine on level ground as shown in the illustration.
3. Put marks on both inner and outer races of the swing bearing to indicate relation of two positions.
4. The bucket should be empty.
Test Procedure (Over Swing):
1. Start the engine and place the power mode selector switch in power Mode III position. Place the engine speed
dial at position "10" (high idle).
2. Move the swing control lever to the RIGHT or LEFT until the machine completes a 180° swing operation.
Return the swing control lever to the NEUTRAL position at the end of the 180° swing operation and measure
the amount of over swing by measuring the distance between the marks on the swing bearing.
NOTE: Use a reference point that is visible from the operator's seat as a indicator of when to stop the 180°
rotation.
Test Procedure (Speed):

1. Move the swing control lever to the LEFT or RIGHT and measure the time it takes to complete a 180° swing
operation.
Swing Speed And Drift (On A Slope)
Measuring the swing speed on a slope will determine if there is a need to check the swing motor and/or anti-
reaction valve. Measuring the swing drift on a slope will determine if there is a need to check the swing parking
brake.
Test Preparation:
1. Place the machine on a 12° slope.
2. Place the implements at maximum reach and fill the bucket with soil. The bucket should be positioned above
the ground to clear any obstructions.
Test Procedure (Speed):

1. Stop the machine on a slope of 12°. Place the upper structure at a 90° angle to the lower structure as shown in
the illustration.
2. Measure the time needed to swing the upper structure 90° counterclockwise. Do the same for a 90° swing
clockwise.
Test Procedure (Drift):

1. Stop the machine on a slope of 12°.
2. Place the upper structure at a 90° angle to the tracks as shown in the illustration.
3. Put marks on the inner and outer races of the swing bearing.
4. Stop the engine.
5. Leave the machine in this position for three minutes, and measure swing drift on the circumference of the
swing bearing.
6. Rotate the upper structure 180° from the original position as described in Step 1.
7. Repeat Steps 2 through 5.
Test Procedure (Drift):

1. Stop the machine on a slope of 12°.
2. Place the upper structure at a 90° angle to the tracks as shown in the illustration.
3. Put marks on the inner and outer races of the swing bearing.
4. Stop the engine.
5. Leave the machine in this position for three minutes, and measure swing drift on the circumference of the
swing bearing.
6. Rotate the upper structure 180° from the original position as described in Step 1.
7. Repeat Steps 2 through 5.
Cylinder Drift
Test Preparation:
2. Place the machine on level ground as shown in the illustration.
3. Fill the bucket with soil.
Test Procedure (For Boom And Stick Cylinders):
1. Fully extend the bucket cylinder.
2. Fully retract the stick cylinder.
3. Raise the boom until its upper surface becomes parallel to the ground.
4. Measure each cylinder's length from pin to pin.
5. Stop the engine.
6. Leave the machine in this position for three minutes, then measure each cylinder's length from pin to pin for
drift.
Test Procedure (For Bucket Cylinder):
1. Fully extend the bucket cylinder.
2. Raise the boom high enough until the stick is perpendicular to the ground.
3. Measure each cylinder's length from pin to pin.
4. Stop the engine.
5. Leave the machine in this position for three minutes, then measure each cylinder's length from pin to pin for
drift.
Cylinder Operating Speed
Test Preparation:
1. Place the machine on level ground.
2. Bucket must be empty.
Test Procedure (Boom Cylinders):

1. Fully retract bucket and stick cylinders.
Extension test;
Measure the time required for the boom cylinders to reach full extension position starting with the bucket on the
ground.
Retraction test;
Measure the time required for the bucket to come in contact with the ground from the full extension position of
the boom cylinders.
Test Procedure (Stick Cylinder):
1. Position the upper surface of the boom parallel to the ground and fully extend the bucket cylinder.
Extension test;
Measure the time required for the stick cylinder to reach full extension position from full retraction position.
Retraction test;
Measure the time required for the stick cylinder to reach full retraction position from full extension position.
Test Procedure (Bucket Cylinder):
1. Position the upper surface of the boom parallel and the stick perpendicular to the ground.
Extension test;
Measure the time required for the bucket cylinder to reach full extension position from full retraction position.
Retraction test;
Measure the time required for the bucket cylinder to reach full retraction position from full extension position.
Release Of Pressure In The Hydraulic System

Release the pressure in the implement hydraulic circuits (boom, stick, and bucket) before any hydraulic lines or
components are disconnected or removed.
1. Fully retract the stick cylinder rod.
2. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.
3. Lower the boom until the bucket is flat on the ground.
4. Shut off the engine and put the hydraulic activation control lever in the UNLOCK position.
5. Move the control levers for boom, stick, and swing to all full stroke positions. This will release any pressure
that might be present in the pilot system.
6. Slowly loosen the air vent plug on the hydraulic tank and release the pressure.
7. Tighten the air vent plug on the hydraulic tank.
8. The pressure in the hydraulic system has been released and lines and components can be removed.
Release Of Air From Main Pumps

When the main pumps have been serviced or the hydraulic oil replaced, remove air from the hydraulic system as
follows;
NOTICE
No attempt should be made to start the engine until the main pumps
have been filled with hydraulic oil, or serious damage can be caused to
hydraulic components.
Pump Compartment
(1) Hose.
1. With the engine stopped, disconnect hose (1) from the top of the main pump. Leave the hose disconnected for
several minutes until the main pumps are filled with oil. Connect hose (1) to the top of the main pumps and start
the engine in low idle and fully raise the boom and hold it in this position.
2. Stop the engine and slowly lower the boom until the bucket is on the ground. This pressurizes the hydraulic
tank.
3. Slowly loosen hose (1) until oil flows out of the hose opening. This is an indication that the air has been
released from the pump.
4. Tighten hose (1).
Pressure Adjustment
Specifications
NOTE: A new or rebuilt machine must perform according to NEW or REBUILD specifications. A machine that
performs beyond SERVICE LIMIT specifications must be checked for improper adjustment, wear, or damage of
relief valves or pumps.
Adjustment Procedures
NOTE: Values given above are approximate. Use a pressure gauge for adjustment.
Relief Valve Adjustment Preparation
Pump Compartment
(1) Tap (power shift pressure). (2) Tap (upper pump). (3) Tap (lower pump).
1. Place the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic System".
3. Connect a 49 000 kPa (7100 psi) pressure gauge to either the main pump tap (2) or tap (3).
4. Connect a 4900 kPa (700 psi) pressure gauge to tap (1)
5. Start the engine and move the stick IN and OUT to its full travel position. Do this operation several times until
the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).
6. Place the power mode selector switch in Mode III position.
7. Place the engine speed dial at position "10". Check that engine speed under no load is at specified rpm with
AEC switch in the OFF position. (Read rpm 3 seconds after the speed dial switch has been placed in position
"10".)
NOTE: See the section, "Operational Test Preparations" for the specified engine rpm for dial position "10".
NOTE: Normal operations (see characteristic curve) of the engine and pumps are necessary for the pressure
adjustment. If the results of the pressure adjustment are not correct, then the engine and pump characteristic
curve needs to be checked.
Temporary Setting Of The Main Relief Valve Pressure
NOTE: The purpose for "Temporary Setting Of The Main Relief Pressure" is done so implement line relief
valves and travel relief valves can be adjusted.
Top Of Main Control Valves
(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.
1. Place the machine on level ground and stop the engine. Release the pressure in the hydraulic system. See the
section in this module, "Release Of Pressure In The Hydraulic System".
2. Slowly move the bucket control lever to the bucket open position (full cylinder rod retraction).
3. Check to be sure the main relief valve pressure setting is 31 400 ± 490 kPa (4550 ± 72 psi).
NOTE: Always make final pressure adjustments on pressure rise.
4. Loosen locknut (5) and turn plunger (4) clockwise until it bottoms out. Tighten locknut (5).
5. Loosen locknut (7) and turn adjuster (6) clockwise a quarter turn. Tighten locknut (7).
Adjustment Of Line Relief Valve Pressure
Preparation
1. Start the service program "Calibration Mode" and keep the power shift pressure constant at 2250 kPa (330
psi). Read the pressure gauge attached at tap (1) to monitor the power shift pressure.
NOTE: For further information of "Calibration Mode", see the section in this module "Calibration Mode".
NOTE: During line relief adjustment, do not turn the engine OFF to prevent a change in power shift pressure.
2. Use the pressure gauge at tap (2) to read the line relief pressure for boom and bucket circuits. Use the pressure
gauge at tap (3) to read the line relief pressure for stick circuit. For line relief pressure settings for the implement
circuits see the section, "Pressure Adjustment, Specifications".
NOTE: After adjustment of the line relief valves, return the main relief pressure to its normal setting.
Main Control Valve Compartment (Viewed From Machine Front)

(9) Line relief valve (bucket cylinder head end). (10) Line relief valve (stick cylinder head end).
NOTE: Rod end line relief valves of boom, stick, and bucket are located under the main control valves.
Right Front Of Swing Motor

(11) Boom drift reduction valve. (12) Line relief valve (boom cylinder head end).
Line Relief Valve (typical all cylinders)

(13) Locknut. (14) Screw.
Adjustment (Stick Cylinder)
1. To adjust the pressure in the stick cylinder rod end, move the stick control lever to full stick OUT (rod
retracted) position. Check the pressure in the stick cylinder rod end at tap (3).
2. Return the stick control lever to the NEUTRAL position. Loosen locknut (13) and turn screw (14) until line
relief valve pressure at tap (3) reads 33 800 ± 1470 kPa (4900 ± 215 psi). Turning screw (14) clockwise
increases the pressure and turning screw (14) counterclockwise decreases the pressure.
3. To adjust the pressure in the stick cylinder head end, move the stick control lever to full stick IN (rod
extended) position. Check the pressure at tap (3).
4. Return the stick control lever to the NEUTRAL position. Adjust the line relief valve pressure in the same
manner as the stick rod end.
NOTE: Always make final pressure adjustment on pressure rise.
Adjustment (Bucket Cylinder)
1. To adjust the pressure in the bucket cylinder head end, move the bucket control lever to full bucket CLOSE
(rod extended) position. Check the pressure in the bucket cylinder head end at tap (2).
2. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve pressure in the same
manner as described for the stick cylinder.
3. To adjust the pressure in the bucket cylinder rod end, move the bucket control lever to full bucket OPEN (rod
retracted) position. Check the pressure at tap (2).
4. Return the bucket control lever to the NEUTRAL position. Adjust the line relief valve pressure to 33 800 ±
1470 kPa (4900 ± 215 psi) using the same procedure as that described for the stick cylinder.
Adjustment (Boom Cylinder)
1. To adjust the pressure in the boom cylinder head end, move the boom control lever to full boom RAISE (rod
extended) position. Check the pressure in the boom cylinder head end at tap (2).
2. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve pressure in the same
manner as described for the stick cylinder.
3. To adjust the pressure in the boom cylinder rod end, move the boom control lever to full boom DOWN (rod
retracted) position. Check the pressure at tap (2).
4. Return the boom control lever to the NEUTRAL position. Adjust the line relief valve pressure to 33 800 ±
1470 kPa (4900 ± 215 psi) using the same procedure as that described for the stick cylinder.
NOTE: If an appropriate location is not available for full retraction of the boom cylinder, reverse the line relief
valves of the head end and rod end by switching the valves. Adjust the pressure of the line relief valve now
attached in the head end. Once adjusted, return the respective relief valves to their original positions and cancel
the function of the service program "Calibration Mode". Refer to the section in this module, "Calibration Mode
Stop Procedure".
Travel Crossover Relief Valve Adjustment
Sprocket (Left Track)

(15) Sprocket. (16) Stopper.
Travel Brake Valve (Left Track)

(18) Screw. (19) Locknut. (20) Crossover relief valve (forward left travel). (21) Crossover relief valve (reverse left travel).
Pump Compartment
Preparation
1. Start Service Program "Calibration Mode" and maintain power shift pressure at 2250 kPa (330 psi). Read the
pressure gauge at tap (1) for the power shift pressure settings.
NOTE: During this test, to prevent a change in power shift pressure do not turn the engine start switch to OFF
position.
2. Block forward left travel, by putting stopper (16) in position on the gear of sprocket (15), as shown above.
Adjustment Procedure
1. Slowly move the left travel control lever to full FORWARD position and check the pressure of crossover
relief valve (20) at tap (3).
2. Return the control lever to the NEUTRAL position and adjust relief valve pressure. To adjust crossover relief
valve (20), loosen locknut (19) and turn screw (18) until the pressure gauge at tap (3) reads 36 800 ± 1470 kPa
(5350 ± 215 psi).
3. Tighten locknut (19) to a torque of 44 ± 5 N·m (32 ± 4 lb ft).
4. Position stopper (16) to block reverse left travel.
5. Slowly move the left travel control lever to full REVERSE position and check the pressure of crossover relief
valve (21) at tap (3). Adjust the pressure of crossover relief valve (21) in the same manner as described for
crossover relief valve (20).
6. Adjust the pressure of crossover relief valves of right travel motor in the same manner as described for the left
travel motor. Use the pressure gauge at tap (3) to read the pressure.
7. After completion of adjustment, stop the function of the service program "Calibration Mode". Refer to the
section "Calibration Mode Stop Procedure".
Swing Motor Relief Valve Pressure Adjustment (Machines With Swing Lock Pin)

(22) Relief valve (right swing). (23) Relief valve (left swing). (24) Locknut. (25) Plug.
Preparation
2. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (3).
3. Start the engine and place the engine speed dial at position "10" with the power mode selector switch at Mode
III position.
5. Place the swing lock pin in the LOCKED position.
1. Slowly move the swing control lever for a full RIGHT swing operation and check the pressure of relief valve
(22) at tap (3).
2. Return the swing control lever to the NEUTRAL position. Loosen locknut (24) and turn plug (25) until line
relief valve pressure at tap (3) reads 24 000 ± 490 kPa (3500 ± 72 psi). Turning plug (25) clockwise increases
the pressure and turning plug (25) counterclockwise decreases the pressure.
3. To adjust the relief pressure for left swing, slowly move the control lever to a full LEFT swing operation and
check the pressure of crossover relief valve (23) at tap (3).
4. Return the swing control lever to the NEUTRAL position. Adjust the relief valve pressure in the same manner
as the swing right relief valve.
NOTE: Always make final pressure adjustment on the pressure rise.
Swing Motor Relief Valve Pressure Adjustment (Machines Without Swing Lock Pin)

(22) Relief valve (right swing). (23) Relief valve (left swing). (24) Locknut. (25) Plug.
Main Control Valve Compartment

(26) Elbow. (27) Pilot line (swing parking brake).
Preparation
4. Start and run the engine at a no-load high idle speed of 1860 ± 50 rpm with the power mode selector switch at
Mode III position.
6. Engage the swing parking brake as follows;
a. Disconnect pilot line (27) from elbow (26).
b. Install a cap (9/16-18HD)(8S4950) on elbow (26). Leave the end of pilot line (27) open to the air.
NOTE: Check to be sure that the swing parking brake is correctly being engaged while the swing control is
activated.
1. Slowly move the swing control lever for a full RIGHT swing operation and check the pressure of relief valve
(22).
2. Return the swing control lever to the NEUTRAL position. Loosen locknut (24) and turn plug (25) until line
relief valve pressure at tap (3) reads 24 000 ± 490 kPa (3500 ± 72 psi). Turning plug (25) clockwise increases
the pressure and turning plug (25) counterclockwise decreases the pressure.
3. To adjust the relief pressure for left swing, slowly move the control lever to a full LEFT swing operation and
check the pressure of crossover relief valve (23).
4. Return the swing control lever to the NEUTRAL position. Adjust the relief valve pressure in the same manner
as the swing right relief valve.
NOTE: Always make final pressure adjustment on the pressure rise.
5. After adjustment, disengage the swing parking brake as follows;
a. Stop the engine and release the pressure in the hydraulic system. See the section in this module, "Release Of
Pressure In The Hydraulic System".
b. Remove the cap (9/16-18HD)(8S4950) from elbow (26).
c. Connect pilot line (27) to elbow (26).
Main Relief Valve Adjustment

NOTE: Pressure adjustments to the main relief valve should be done by first adjusting the travel operation of
the main relief valve and then adjusting the implement operation of the main relief valve. Any adjustment to the
travel operation of the main relief valve will change the pressure setting to the implement operation of the main
relief valve.
Top Of Main Control Valves

(4) Plunger. (5) Locknut. (6) Adjuster. (7) Locknut. (8) Main relief valve.
Preparation
3. Start the engine and place the engine speed dial at position "10" with the power mode selector switch at Mode
III position.
Adjustment Procedure (In Travel Operation)

1. Block forward left travel by putting stopper (16) in position on the gear of sprocket (15).
Pump Compartment
2. Slowly move the left travel control lever to full FORWARD position and check main relief valve pressure at
tap (3).
3. Return the control lever to the NEUTRAL position.
4. Loosen locknut (7) and turn adjuster (6) until the pressure gauge at tap (3) reads 34 300 ± 490 kPa (4950 ± 72
psi). Tighten locknut (7) to a torque of 59 ± 10 N·m (44 ± 7 lb ft).
Reference: Turning adjuster (6) clockwise increases the pressure. Turning adjuster (6) counterclockwise
decreases the pressure.
Adjustment Procedure (Implement Operation)
1. Slowly move the control lever to full bucket OPEN (bucket cylinder full retraction) position and check the
main relief valve pressure at tap (2).
2. Return the control lever to the NEUTRAL position and adjust main relief valve pressure to 31 400 ± 490 kPa
(4550 ± 72 psi).
3. To adjust, loosen locknut (5) and turn plunger (4) until the pressure gauge at tap (2) reads 31 400 ± 490 kPa
(4550 ± 72 psi). Tighten locknut (5) to a torque of 50 ± 10 N·m (37 ± 7 lb ft).
Reference: Turning plunger (4) clockwise increases the pressure. Turning plunger (4) counterclockwise
Pilot Relief Valve Adjustment
Preparation
Pilot Oil Manifold Compartment

(28) Pilot relief valve. (29) Tap. (30) Locknut. (31) Screw.
3. Connect a 49 000 kPa (7100 psi) pressure gauge to either the main pump tap (2) or tap (3).
4. Connect a 4900 kPa (700 psi) pressure gauge to tap (1) and tap (29).
5. Start the engine and move the stick IN and OUT to its full travel position. Do this operation several times until
the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).
6. Place the power mode selector switch in Mode III position.
7. Place the engine speed dial at position "10". Check that engine speed under no load is at specified rpm with
AEC switch in the OFF position. (Read rpm 3 seconds after the speed dial switch has been placed in position
"10".)
NOTE: See the section, "Operational Test Preparations" for the specified engine rpm for dial position "10".
NOTE: Normal operations (see characteristic curve) of the engine and pumps are necessary for the pressure
adjustment. If the results of the pressure adjustment are not correct, then the engine and pump characteristic
curve needs to be checked.
1. Loosen locknut (30) of pilot relief valve (28).
2. Turn screw (31) until the pressure gauge reads 3450 ± 200 kPa (500 ± 30 psi).
Reference: Turning screw (31) clockwise increases the pressure and turning screw (31) counterclockwise
Adjustment Of Automatic Travel Speed Travel Change Valve
Preparation
1. Reset main relief valves. Refer to the section, "Main Relief Valve Adjustment".
Pump Compartment
(1) Tap (lower pump).
3. Install pressure gauge (8T0861)[60 000 kPa (8700 psi)] at tap (1) of the lower pump with two coupler
assemblies (6V4143) and hose assembly (6V3014).

(28) Pilot relief valve. (29) Tap. (30) Locknut. (31) Screw.
4. Install pressure gauge (8T0856)[6000 kPa (870 psi)] into coupler assembly (6V4143). Connect coupler
assembly to hose assembly (6V3014) and install at tap (29) of pilot oil manifold using second coupler assembly.
Travel Motor (Left Track)

(32) Signal line (two speed travel).
5. Disconnect signal line (32) from the travel motor. Attach a swivel tee (9U7845 or 8T8902) to signal line port
on travel motor. Install a nipple (6V3965) and o-ring seal (3J1907) to tee. Connect pressure gauge (8T0856)
[6000 kPa (870 psi)] to hose assembly and install on tee. Reconnect signal line (32) to tee on travel motor signal
line port.
6. Start the engine and raise the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F).
7. Place the power mode selector switch in power Mode III position and maintain the maximum no load speed of
1860 ± 50 rpm with AEC switch OFF.

8. Block the forward left travel by putting stopper (5) in position on the gear of sprocket (4), as shown above.
9. Place the travel speed control switch in HIGH (rabbit) position.
10. The pressure gauge at tap (2) should read 3450 kPa (500 psi).

(6) Automatic travel speed change valve. (7) Screw. (8) Locknut.
1. While reading the pressure gauges connected to the signal pressure line (32) and to tap (1), slowly move the
left travel control lever/pedal to the FORWARD position. When the pressure at tap (1) reads 30 600 ± 1180 kPa
(4450 ± 170 psi), the pressure gauge connected to signal line (32) should reduce to 0 kPa (0 psi).
NOTE: These pressures indicate that the automatic travel speed change valve has caused the travel motor to
shift to LOW (tortoise) speed.
2. Slowly return the left travel control lever/pedal to the NEUTRAL position.
3. If the pressure gauge connected to signal line (32) does not read 0 kPa (0 psi) at the time the system pressure
at tap (1) reads 30 600 ± 1180 kPa (4450 ± 170 psi), then adjust automatic travel speed change valve (6) as
follows:
a. Loosen locknut (8) and turn screw (7) until the pressure gauge connected to line (30) reads 0 kPa (0 psi) when
the pressure gauge at tap (1) reads 30 600 ± 1180 kPa (4450 ± 170 psi).
b. Tighten locknut (8) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).
NOTE: Turning screw (7) clockwise increases the pressure. Turning screw (7) counterclockwise decreases the
pressure.
4. Repeat Step 1.
5. Slowly move the travel control lever/pedal towards the NEUTRAL position until the pressure gauge at tap (1)
decreases to 15 300 ± 490 kPa (2200 ± 72 psi). Now the pressure gauge connected to signal line (32) will read
3450 kPa (500 psi).
NOTE: These pressures indicate when the automatic travel speed change valve causes the travel motor to shift
to HIGH (rabbit) speed.
Pump Flow Tests
Controller Compartment
(1) Controller alarm lamp. (2) Controller.
Right Console
(3) Monitor. (4) Monitor panel.
NOTE: Before starting pump flow tests, check the action alarm indicators on controller (2) and monitor panel
(4). If they indicate normal, then perform the operational tests.
NOTE: If operational tests (for example, cycle times) indicates that a slow implement problem is common to
the circuits of one pump, then the problem is most likely in the hydraulic system. Then perform the "Pump Flow
Tests".
NOTE: If the operational tests indicate a implement speed problem common to both pump circuits, then the
engine, fuel, or working altitude may be the problem.
Main Pump Constant Horsepower Control Test
Illustration Of Flow Meter Tool Layout (Constant Horsepower Control Test) (Main Pump)
(1) Portable hydraulic tester. (2) O-ring. (3) Adapter. (4) O-ring. (5) Nipple assembly. (6) Coupler assembly. (7) Reusable coupling. (8)
Sleeve. (9) Hose. (10) Fitting. (11) Plug. (12) O-ring. (13) Bolt. (14) Washer. (15) Flange. (16) Adapter. (17) Rectangular seal. (18) Cover.
(19) Coupling assembly. (20) O-ring. (21) Tee. (22) Upper pump. (23) Lower pump. (24) Delivery line (upper pump). (25) Delivery line
(lower pump). (26) Return line. (27) Swing motor.
Preparation (Upper Pump)
Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Upper Pump)
(1) Portable hydraulic tester (flow meter). (9) Hose. (18) Cover. (22) Upper pump. (23) Lower pump. (24) Delivery line (upper pump).
(25) Delivery line (lower pump). (27) Swing motor. (28) Multitach. (29) Main control valves. (30) Gauge. (31) Tap (upper pump). (32)
Gauge. (33) Tap (power shift pressure). (34) Tap (lower pump). (35) Engine.
Pump Compartment
(9) Hose (upper pump charge line). (22) Upper pump. (23) Lower pump. (24) Delivery line (upper pump). (31) Tap (upper pump). (33)
Tap (power shift pressure). (34) Tap (lower pump).
Portable Hydraulic Tester (Flow Meter)

(1) Portable hydraulic tester (flow meter). (9) Hose. (28) Multitach. (36) Valve (flow meter).

(9) Hose (return line from flow meter). (21) Tee. (26) Return line. (27) Swing motor.
To prevent personal injury or equipment damage from failure of the

flow meter or associated circuit components because of blocked pump
flow, make sure before starting the engine that the flow meter valve is
fully open (turned counterclockwise).
1. Position the machine on level ground and stop the engine.
NOTE: The bolts that retain the gaurd between the pumps and engine may require loosening to provide
sufficient clearance to install tooling.
3. Install the following tools in accordance with flow meter tool layout illustration and circuit diagram.
a. Disconnect delivery line (24) from upper pump (22).
b. Install cover (18), O-ring seal (17), flange (15), bolt (14), and washer (13) to the end of delivery line (24).
c. Disconnect return line (26) from swing motor (27).
d. Install tee (21) and two O-ring seals (20) to the swing motor (27) return port. Connect return line (26) to tee
(21).
e. Connect portable hydraulic tester (1) between upper pump (22) and tee (21) with two hoses (9).
f. Install pressure gauge (32) at power shift pressure tap (33). Install pressure gauge (30) at upper pump tap (31).
[A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (32) and (30).] Tap (33) is used
to measure the power shift pressure. Taps (31) and (34) are used to measure the upper pump and lower pump
delivery pressure.
g. Install multitach group (28) on engine (35). This is used to read engine speed.
4. Start the engine and place the power mode selector switch in Mode III position.
5. Place the engine speed dial at position "10" and maintain the maximum no load speed at 1860 ± 50 rpm with
the AEC switch OFF. (Read the rpm three seconds elapsed time after the engine speed dial has been placed in
position "10").
6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil temperature, move the stick
IN and OUT its full travel several times.
Preparation (Lower Pump)
Pump Compartment
(9) Hose (lower pump charge line). (23) Lower pump. (25) Delivery line (lower pump). (33) Tap (power shift pressure). (34) Tap (lower
pump).
Perform the same preparation as that described for the upper pump flow test under constant horsepower control
except Step 3. Use the following procedure in replacement for Step 3, for the lower pump (23).
a. Disconnect delivery line (25) from lower pump (23).
(21).
e. Connect portable hydraulic tester (1) between lower pump (23) and tee (21) with two hoses (9).
f. Install pressure gauge (32) at power shift pressure tap (33). Install pressure gauge (30) at lower pump tap (34).
[A 49 000 kPa (7100 psi) pressure gauge can be used in place of pressure gauge (32) and (30).] Tap (33) is used
to measure the power shift pressure. Taps (31) and (34) are used to measure the upper pump and lower pump
delivery pressure.
g. Install multitach group (28) on engine (35). This is used to read engine speed.
Test Procedure
NOTE: Perform the upper and lower pump flow tests one at a time.

flow, make sure before starting the engine that the flow meter valve (36)
is fully open (turned counterclockwise).
To prevent personal injury and/or equipment damage from failed lines

or components while the flow meter is returned to the open flow
position after a flow test, slowly open the flow meter valve and monitor
pump flow at the same time to make sure flow increases. If pump flow
does not increase as the flow meter is opened, shut the engine off and
determine what is causing the pump not to upstroke.
1. With the engine running, start the service program "Calibration Mode" and maintain the power shift pressure
at a constant pressure of 1770 ± 50 kPa (255 ± 7 psi). The power shift pressure is read at tap (33), using pressure
gauge (32).
NOTE: During this test, do not turn the starter switch to the OFF position to prevent any change in power shift
pressure. See the section in this module "Calibration Mode Stop Procedure".
NOTE: To start service program "Calibration Mode" see the section in this module "Calibration Mode Start-up".
2. Slowly turn valve (36) of portable hydraulic tester (1) clockwise and record pump flow at each of the
following pressure points. Use pressure gauge (32) at tap (33) for this pressure reading.
P-Q Characteristic Curve
NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To get more accurate test
results, each of measurements should be corrected by calculating as follows.
Flow corrected = (Flow measured × 1800) ÷ RPM measured
3. Any flow readings must be done only in upstroke (pressure rise).
4. The pump flow changes approximately 10 liter/min. (2.6 U.S. gpm) for each 100 kPa (14 psi) of power shift
pressure.
Negative Flow Control Test
Illustration Of Flow Meter Tool Layout 1 (Negative Flow Control Test) (Main Pump)
(1) Portable hydraulic tester. (2) O-ring. (3) Adapter. (4) O-ring. (5) Nipple assembly. (6) Coupler assembly. (7) Reusable coupling. (8)
Sleeve. (9) Hose. (10) Fitting. (11) Plug. (12) O-ring. (13) Bolt. (14) Washer. (15) Flange. (16) Adapter. (17) Rectangular seal. (18) Cover.
(19) Coupling assembly. (20) O-ring. (21) Tee. (22) Upper pump. (23) Lower pump. (24) Delivery line (upper pump). (25) Delivery line
(lower pump). (26) Return line. (27) Swing motor.
Preparation (Upper Pump)
Circuit Diagram For Negative Flow Control Test (Upper Pump)

(1) Portable hydraulic tester. (9) Hose. (18) Cover. (22) Upper pump. (23) Lower pump. (24) Delivery line (upper pump). (25) Delivery
line (lower pump). (27) Swing motor. (28) Multitach. (29) Main control valves. (30) Gauge. (31) Tap (upper pump). (32) Gauge. (33) Tee.
(34) Tap (lower pump). (35) Tap. (36) Pilot oil manifold. (37) Negative flow control line. (38) Test hose. (39) Plug. (40) Negative flow
control line.
Pump Compartment
(9) Hose (upper pump charge line). (22) Upper pump. (23) Lower pump. (24) Delivery line (upper pump). (31) Tap (upper pump). (37)
Negative flow control line (upper pump).

(35) Tap.
Portable Hydraulic Tester (Flow Meter)

(1) Portable hydraulic tester (flow meter). (9) Hose. (28) Multitach. (41) Valve (flow meter).

(9) Hose (return line from flow meter). (21) Tee. (27) Swing motor. (26) Return line.
Illustration Of Flow Meter Tool Layout 2 (Negative Flow Control Test) (Main Pump)
(12) O-ring seal. (22) Upper pump. (23) Lower pump. (32) Gauge. (33) Tee. (35) Tap. (36) Pilot oil manifold. (37) Negative flow control
line. (38) Hose assembly. (40) Negative flow control line. (42) Coupler assembly. (43) Nipple. (44) O-ring seal. (45) Cap. (46) Plug.
1. Position the machine on level ground and stop the engine.
2. Release the pressure in the hydraulic system. See the section in this module "Release Of Pressure In The
Hydraulic System".
3. Install the following tools in accordance with flow meter tool layout illustration 1, flow meter tool layout
illustration 2, and circuit diagram.
a. Disconnect delivery line (24) from upper pump (22).
(21).
e. Connect portable hydraulic tester (1) between upper pump (22) and tee (21) with two hoses (9).
f. Remove negative flow control line (37) from upper pump (22) and install plug (46) in open end of negative
flow control line (37). Install tee (33) and o-ring seal (44) to negative flow control line (37) port of upper pump
(22). Install nipple (43) and o-ring seal (12) to tee (33).
g. Install two couplers (42) to test hose assembly (38) and connect hose to nipple (43).
h. Connect hose (38) to tap (35) of pilot oil manifold (36).
i. Install second tee (33) to first tee with o-ring seal (44). Install nipple (43) and o-ring seal (12) in tee (33).
j. Install pressure gauge (32) to second tee (33). Install pressure gauge (30) at upper pump tap (31). [A 49 000
kPa (7100 psi) pressure gauge can be used in place of pressure gauge (32) and (30).] Tap (35) is used to measure
the negative control flow. Taps (31) and (34) are used to measure the upper pump and lower pump delivery
pressure.
k. Install o-ring seal (44) and cap (45) on open end of tee (33).
l. Install multitach group (28) on to the engine. This is used to read engine speed.
4. Start the engine and place the power mode selector switch in Mode III position.
5. Place the engine speed dial at position "10" and maintain the maximum no load speed at 1860 ± 50 rpm with
the AEC switch OFF. (Read the rpm three seconds elapsed time after the engine speed dial has been placed in
position "10").
6. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To increase the oil temperature, move the stick
IN and OUT its full travel several times.
Preparation (Lower Pump)
Pump Compartment
(9) Hose (lower pump charge line). (23) Lower pump. (25) Delivery line (lower pump). (34) Tap (lower pump). (40) Negative flow control
line (lower pump).
Perform the same preparation as that described for the upper pump negative pump flow control test except Step
3. Use the following procedure in replacement for Step 3, for the lower pump (23).
a. Disconnect delivery line (25) from lower pump (23).
(21).
e. Connect portable hydraulic tester (1) between lower pump (23) and tee (21) with two hoses (9).
f. Remove negative flow control line (40) from lower pump (23) and install plug (46) in open end of negative
flow control line (40). Install tee (33) and o-ring seal (44) to negative flow control line (40) port of lower pump
(23). Install nipple (43) and o-ring seal (12) to tee (33).
g. Install two couplers (42) to test hose assembly (38) and connect hose to nipple (43).
h. Connect hose (38) to tap (35) of pilot oil manifold (36).
i. Install second tee (33) to first tee with o-ring seal (44). Install nipple (43) and o-ring seal (12) in tee (33).
j. Install pressure gauge (32) to second tee (33). Install pressure gauge (30) at lower pump tap (34). [A 49 000
kPa (7100 psi) pressure gauge can be used in place of pressure gauge (32) and (30).] Tap (35) is used to measure
the negative control flow. Taps (31) and (34) are used to measure the upper pump and lower pump delivery
pressure.
k. Install o-ring seal (44) and cap (45) on open end of tee (33).
l. Install multitach group (28) on to the engine. This is used to read engine speed.
Test Procedure
NOTE: Perform the upper and lower pump negative flow control tests one at a time.

flow, make sure before starting the engine that the flow meter valve (41)
is fully open (turned counterclockwise).
To prevent personal injury and/or equipment damage from failed lines

or components while the flow meter is returned to the open flow
position after a flow test, slowly open the flow meter valve and monitor
pump flow at the same time to make sure flow increases. If pump flow
does not increase as the flow meter is opened, shut the engine off and
determine what is causing the pump not to upstroke.
1. Place the power mode selector switch in the Mode III position.
2. Negative flow control test for the upper and lower pumps must be done one at a time.
3. Slowly turn valve (41) of portable hydraulic tester (1) clockwise until the pump delivery pressure setting is
6850 kPa (1000 psi).
4. Adjust pilot relief valve of pilot oil manifold (36) until pressure gauge (32) connected to tee (33) reads 2550
kPa (370 psi).
5. Record the negative control flow at the following pressure point.
P-Q Characteristic Curve [Negative Flow Control at 6850 kPa (1000 psi) Pump Delivery Pressure]
NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To get more accurate test
results, measured flow should be corrected by calculating as follows:
Flow corrected = (Flow measured × 1800) ÷ rpm measured
NOTE: Flow measurements must be taken only in pressure rise.
Pump Output Flow Adjustment
Pump Compartment
(1) Locknut. (2) Setscrew. (3) Locknut. (4) Setscrew.
Output flow adjustment procedure for the upper and lower pumps is the same. Setscrew (2) and locknut (1) are
for the upper pump and setscrew (4) and locknut (3) are for the lower pump.
Upper Pump Adjustment

1. Loosen locknut (1).
2. Turn setscrew (2) until adjusted to the correct specification.

Turning setscrew (2) 1/4 turn clockwise increases the flow rate approximately 18 liter/min (4.8 U.S.gpm) at a
system pressure of 14 700 kPa (2150 psi) or 17 700 kPa (2550 psi) where the first stage spring activates.
Turning setscrew (2) 1/4 turn clockwise increases the flow rate approximately 7 liter/min (1.9 U.S.gpm) at a
system pressure of 23 500 kPa (3400 psi) or 34 300 kPa (5000 psi) where the second stage spring activates.
Turning setscrew (2) counterclockwise decreases the flow rate by the same amount as shown in the clockwise
rotation.
Lower Pump Adjustment

To adjust the lower pump output flow do the same as that described above using setscrew (4) and locknut (3) in
place of setscrew (2) and locknut (1).
Maximum Pump Flow Adjustment
Pump Compartment
(5) Locknut. (6) Setscrew. (7) Setscrew. (8) Locknut.
Maximum pump flow adjustment procedure for the upper and lower pumps is the same. Setscrew (6) and
locknut (5) are for the upper pump and setscrew (7) and locknut (8) are for the lower pump.
Turning setscrew (6) 1/4 turn clockwise increases the flow rate approximately 1.3 liter/min (0.3 U.S.gpm).
Turning setscrew (6) 1/4 turn counterclockwise decreases the flow rate approximately 1.3 liter/min (0.3
U.S.gpm).
To adjust the lower pump maximum flow do the same as that described above using setscrew (7) and locknut (8)
in place of setscrew (6) and locknut (5).
Negative Flow Control Adjustment

Pump Compartment
(9) Setscrew. (10) Locknut. (11) Setscrew. (12) Locknut.

Negative flow control adjustment procedure for upper and lower pumps is the same. Use setscrew (9) for the
upper pump and setscrew (11) for the lower pump.
Turning the setscrew 1/4 turn clockwise decreases the flow rate approximately 4 liter/min (1.1 U.S.gpm) at a
system pressure of 2550 kPa (370 psi).
Turning the setscrew 1/4 turn counterclockwise increases the flow rate approximately 4 liter/min (1.1 U.S.gpm)
at a system pressure of 2550 kPa (370 psi).
To adjust the lower pump negative flow control do the same as that described above using setscrew (11) and
locknut (12) in place of setscrew (9) and locknut (10).
Copyright 1993 - 2019 Caterpillar Inc. Fri Jan 25 2019 15:00:54 GMT-0300 (hora de verano de Chile)
Todos los derechos reservados.
r120jr6
Red privada para licenciados del SIS.

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25/1/2019 Búsqueda avanzada de texto completo - SENR6044 - 320, 320 L AND 320 N, AND 320 S EXCAVATORS HYDRAULIC AND

YDRAULIC AND ELE

1. Pruebas y ajustes del sistema electrónico

Sistema de control electronico

1. Presión de cambio de potencia.

4. Temperatura del aceite hidráulico.

Modo de inicio de datos

Panel del monitor electrónico (modo de inicio de datos)

Si el interruptor (17) se mantiene presionado demasiado tiempo, la visualización de caracteres se secuenciará a

Selección de función de modo de datos

Panel de monitor electrónico (Selección de función de modo de datos)

Presión de cambio de potencia

Panel del monitor electrónico (presión de cambio de potencia)

La velocidad del motor

Panel del monitor electrónico (Velocidad del motor)

Panel del monitor electrónico (Temperatura del refrigerante del motor)

Temperatura del aceite hidráulico

Panel de monitor electrónico (Temperatura del aceite hidráulico)

Conversión A / D (Analógica / Digital)

Panel de monitor electrónico (conversión A / D)

Códigos de error en tiempo real

Panel del monitor electrónico (códigos de error en tiempo real)

NOTA: Un código de visualización de [E00] indica que no hay errores de sistema.

La siguiente tabla proporciona una lista de los 21 "puertos" y sus componentes:

[1 1]: El dial de velocidad del motor está en la posición "1".

[110]: El dial de velocidad del motor está en la posición "10".

[2En]: El interruptor de presión de desplazamiento está en ON.

[2oF]: El interruptor de presión de desplazamiento está apagado.

Pantalla de control de salida

Panel de monitor electrónico (pantalla de control de salida)

[L00]: El control de salida es normal.

NOTA: [L b] se muestra solo cuando uno de los controles está activado.

Procedimiento de parada de modo de datos

Panel de monitor electrónico (Procedimiento de parada)

Utilice cualquiera de los dos métodos siguientes.

1. Gire el interruptor de arranque del motor a la posición de APAGADO.

Modo de calibracion Puesta en marcha

Panel de monitor electrónico ( modo de calibración)Puesta en marcha)

Modo de calibracion Selección de funciones

Panel de monitor electrónico (selección de función)

Maquina y modelo de motor

Panel de monitor electrónico (modelo de máquina y motor)

Versión de software del controlador / monitor

Panel del monitor electrónico (versión de software del controlador / monitor)

Panel de monitor electrónico (Registro de errores)

* Interruptor AEC (31)

Prueba de salida digital

Panel de monitor electrónico (Prueba de salida digital)

Los "puertos" y sus componentes se muestran en el siguiente cuadro:

Válvula reductora proporcional prueba de barrido

Conector del compartimiento del colector de aceite piloto (39).

1. Detenga el motor y desconecte el conector (39) de la válvula reductora proporcional.

2. Conecte el arnés de prueba al conector (39).

Compartimiento de la bomba principal

4. El interruptor de respaldo de la bomba debe estar en la posición "AUT".

6. Caliente el aceite hidráulico a la temperatura normal de funcionamiento.

7. Haga funcionar el motor a las rpm máximas sin carga.

8. Todos los controles deben estar en la posición NEUTRAL.

Panel del monitor electrónico (Prueba de barrido proporcional de la válvula reductora)

9. Inicie la "Prueba de barrido proporcional de la válvula reductora" de la siguiente manera:

Cambio de velocidad del motor

Panel del monitor electrónico (cambio de velocidad del motor)

5. La visualización de caracteres (4) se incrementará en 1 (10 rpm).