Test Procedure of BL70/71

Tests
1. Engine Tests
2. Transmission Tests
3. Hydraulic Tests
3.1. Servo Pressure
3.2 Stand by situation
3.3 delta p Pressure, setting of the spring in the FR-valve
3.4 Power regulation, setting of the spring in the LR-valve
3.5 Max. Hp Pressure, setting of the relief-valve in the LS-line
3.6 Setting of the pressure limitation of the steering unit
3.7 Max. Pump flow-check
3.8 Pump power regulation-check
3.9. Hammer valve settings
4. Stall tests

Note: for all tests the Engine has to be warm, oil-levels must be ok,

Test Procedure BL71

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1. Engine
Test conditions:
- warm Engine
- Engine oil-level must be ok
- Engine speed is read on the tachometer on the right side console in the cabin

RPM Test
Tested Engine rpm

Expected Engine rpm

Low idle

.......................rpm

900 rpm 0 / +50

High idle

.......................rpm

2350 rpm 0 / +40

Fuel Pressure
- remove the plug near the fuel filter
- fit Minime M12x1,5
- read of pressure at:
Tested Fuel Pressure

Expected Fuel Pressure

Low idle

.......................bar

~ 3bar

High idle

.......................bar

~ 5bar

Engine Oil Pressure

- remove the sensor near the oil filter
- fit Minime M14x1,5
- read of pressure at:
Tested Oil Pressure

Expected Oil Pressure

Low idle

.......................bar

min 0,8 bar

RPM > 1100

.......................bar

~ 4,5 bar

Test Procedure BL71

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3 Hydraulic Tests
3.1. Servo Pressure
Test conditions:
- Hyd.- Oil temperature

ca. 40 - 50 C (+/- 5C)

- Pressure is checked at servo pressure check port near the servo pump
- Engine RPM is read on the tachometer on the right side console in the cabin
Test
Engine Speed

Tested Pressure

2200 rpm

Expected Pressure

.........bar

39 bar 0/+5

3.2. Stand-by situation

Test conditions:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- delta p Pressure is calculated: Hp Ls = delta p
- Hp-Pressure is checked at Hp pressure check port near the main control valve
- LS-Pressure is checked at Ls pressure check port near the main control valve
.- Engine speed is read on the tachometer on the right side console in the cabin
- Checked in stand by situation, no function is in use
Test
Engine RPM

Ca 900 rpm

Tested Pressure

Expected Pressure

Hp

Ls

delta p

....bar

....bar

.....bar

Test Procedure BL71

Hp
~32 bar

Ls

delta p

~10 bar

~22 bar

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3.3. Setting of the spring in the FR-valve (delta p)

Test conditions:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- Delta p Pressure is calculated: Hp Ls = delta p
- Hp-Pressure is checked at Hp pressure check port near the main control valve
digital pressure check tool
- LS-Pressure is checked at Ls pressure check port near the main control valve
- Engine speed is read on the tachometer on the right side console in the cabin
- Hp pressure must be below 100 bar to avoid being involved in power regulation of the
pump
- Delta p is checked while moving one function with a slow and constant speed
- Raise up the boom with the extendable dipper fully retracted and the dipper arm fully
open
Test
Engine RPM

Tested Pressure, delta p

Ca 2350 rpm

........bar

Expected Pressure, delta p

21 bar +/- 2 bar

Note: Some denominations have changed as shown below

LR

to

FR1

Flow and Power regulation Valve,

commands the Pump to reduce the flow to
stay below the max. hyd. Power

FR

to

FR2

Flow regulation Valve, commands the

pump to give the requested flow

Test Procedure BL71

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3.4. Setting of the spring in the LR-valve (FR1)

Test conditions:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- Disconnect plug at LR Valve and fit a hose which goes pressureless into the hyd.-tank
- One function (stabilizer for example) must be permanently end of stroke
- Hp-Pressure is checked at Hp pressure check port near the main control valve l
- Engine RPM is read on the tachometer on the right side console in the cabin
Test
Engine Speed

Tested Pressure, Hp

Ca 2350 rpm

Expected Pressure, Hp

........bar

18 bar +/- 3 bar

3.5. Max. Hp Pressure, setting of the relief-valve in the LS-line

Test conditions:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- Hp-Pressure is checked at Hp pressure check port near the main control valve
- LS-Pressure is checked at Ls pressure check port near the main control valve
- Engine speed is read on the tachometer on the right side console in the cabin
- Checked under load, one function (stabilizer for example) end of stroke
Test
Engine Speed

Ca 2350 rpm

Tested Pressure

Expected Pressure

Hp

Ls

Hp

Ls

.......bar

.......bar

250 bar +/-5

(Hp 21) bar

Test Procedure BL71

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3.6. Setting of the pressure limitation of the steering unit

Test conditions:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- Hp-Pressure is checked at Hp pressure check port near the main control valve
- LS-Pressure is checked at Ls pressure check port near the main control valve
- Engine speed is read on the tachometer on the right side console in the cabin
- Checked with steering cylinder permanently end of stroke

Test
Engine RPM
Ca 2350 rpm

Tested Pressure
Hp
Ls

Expected Pressure
Hp

Ls

..... bar

175 bar +0/-5

(Hp 21)bar

..... bar

Test Procedure BL71

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Note:
Before doing flow checks, please check the cycle times. It proves that flows
(apart from max pump flow) are correct without opening the hydraulic
circuit.
3.7. Max. Pump flow-check
Test conditions:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
Procedure (Flow meter with adjustable restrictor and temperature sensor needed)
- disconnect hose of Boom rod side and close cylinder with plug
- disconnect hose of Dipper rod side and close cylinder with plug
- fit the hoses to the inlet side of the Flowmeter with the adjustable restrictor
- For return line use hammer return line
- Hp-Pressure is checked at Hp pressure check port near the main control valve
- Engine speed is read on the tachometer on the right side console in the cabin
- Fully open dipper cylinder and boom cylinder valve
- Adjust the restrictor to the specified pressure and read of the flow
Test
Engine Speed
Ca 2350 rpm

spec. Pressure Hp
100 bar

Tested Flow

Expected Flow

........... l/min

162 l/min 0/+5

Test Procedure BL71

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Note:
Before doing flow checks, please check the cycle times. It proves that flows
(apart from max pump flow) are correct without opening the hydraulic
circuit.
3.8. Pump power regulation-check
Same conditions and procedure like 8, but:
!!adjust the restrictor to the specified flow and than read of the pressure!!
Loader mode
1. no gear selected on right hand gear lever (Powershuttle),
2. forward/reverse lever engaged into forward/reverse
Engine RPM

spec. Flow

Tested Pressure Hp

Expected Pressure Hp

Ca 2350 rpm

130 l/min

........... bar

115 bar +/-15

Ca 2350 rpm

84 l/min

........... bar

195 bar +25/-15

Excavator mode
1. no gear selected on right hand gear lever
2. forward/reverse lever in neutral position
3. Hydraulic oil temperature below 90C (97C for Phase II)
Engine RPM

spec. Flow

Tested Pressure Hp

Expected Pressure Hp

Ca 2350 rpm

140 l/min

........... bar

185 bar +15/-25

Ca 2350 rpm

107 l/min

........... bar

227 bar +/-25

Note: Both modes are related together.

Test:
At low idle, swing excavator from left to right engine must not stall.
At 1800 rpm put the excavator bucket end of stroke and open the dipper (retract cylinder). Engine
rpm must not go under 1600 rpm.

Test Procedure BL71

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3.9. Hammer valve settings

Test conditions:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)

Procedure Hammer relief valve

- fit a flow meter with adjustable restrictor and pressure sensor on the hammer quickcouplers
- Hp-Pressure is checked at Hp pressure check port near the main control valve
- One function (stabilizer for example) must be permanently end of stroke
- Press hammer button on the floor mat
- Adjust the restrictor to the max. pressure and read of the pressure in the hammer line
- Engine speed is read on the tachometer on the right side console in the cabin
Test Hammer relief valve
Engine Speed

Tested pressure
in hammer line

Ca 2350 rpm

........... bar

Expected Pressure
210 bar

Procedure Hammer flow

- fit a flow meter with adjustable restrictor and pressure sensor on the hammer quick
Couplers
- Hp-Pressure is checked at Hp pressure check port near the main control valve
- One function (stabilizer for example) must be permanently end of stroke
- Press hammer button on the floor mat
- adjust the restrictor to the spec. pressure and read of the flow in the hammer line
- Engine speed is read on the tachometer on the right side console in the cabin
Test Hammer flow
Engine Speed
Ca 2350 rpm

spec. Pressure
in hammer line
170 bar

Tested flow
in hammer line
........... l/min

Test Procedure BL71

Expected flow
in hammer line
110 l/min

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4. Stall tests
Test conditions hydraulic stall:
- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- warm Engine and transmission
- max Engine RPM, 2350 rpm
- curl loader bucket to end of stroke
- Engine RPM is read on the tachometer on the right side console in the cabin
Engine RPM

Tested hyd. Stall speed

Ca 2350 rpm

........ rpm

Expected hyd. Stall speed

2250 rpm +/- 50

Test conditions Torque Converter stall:

- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- warm Engine and transmission
- select parking brake on, engage gear lever into forth, max. Engine RPM, engage
forward/reverse lever into forward
- Engine speed is read on the tachometer on the right side console in the cabin
Engine RPM

Tested T. C. Stall speed

Ca 2350 rpm

........ rpm

Expected T. C. Stall speed

2100 rpm +/- 50

Test conditions Combined stall:

- Hyd Oil temperatureca. 40 - 50 C (+/- 5C)
- warm Engine and transmission
- select parking brake on, engage gear lever into forth, max. Engine RPM, curl loader
bucket to end of stroke, engage forward/reverse lever into forward
- Engine speed is read on the tachometer on the right side console in the cabin
Engine RPM
Ca 2350 rpm

Tested combined Stall speed

Expected combined Stall speed

......... rpm

1800 rpm +/- 50

Note:
The engine can have different results during the run in period.
The tachometer has a tolerance about +/- 50 rpm.

Test Procedure BL71

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