320cl Hydraulic System-testing&Adjusting

CATERPILLAR
RENR3817-02
September 2001
320C Excavator Hydraulic System

ANB1-Up (Machine)
BCB1-Up (Machine)
BDB1-Up (Machine)
AMC1-Up (Machine)
BBC1-Up (Machine)
BDC1-Up (Machine)
CCD1-Up (Machine)
ALF1-Up (Machine)
BEF1-Up (Machine)
AKH1-Up (Machine)
BER1-Up (Machine)
BPR1-Up (Machine)
BRX1-Up (Machine)
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death couid occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as
"DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.
WARNING
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
WARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
3
Hydraulic System
Table of Contents
Table of Contents
Testing and Adjusting Section
Testing and Adjusting
General Testing and Adjusting Information
Visual Inspection
Hydraulic System Pressure - Release
Main Hydraulic Pump Air Pressure - Purge
4
4
4
7
Performance Tests
Operational Checks
9
Engine Performance - Test (Engine Speed)
9
Travel on Level Ground - Test (Optional Test)
10
Travel on Level Ground - Test
11
Machine Drift on a Slope - Check
12
Swing Speed and Overswing on Level Ground Check
13
Swing Speed and Swing Drift on a Slope - Check ..14
Cylinder Drift - Check (Loaded Bucket)
15
Cylinder Drift - Check (Empty Bucket)
16
Cylinder Speed - Check
17
Hydraulic Pressure Adjustments
Required Tools
Relief Valve (Pilot) - Test and Adjust
Relief Valve (Main) - Test and Adjust
Relief Valve (Crossover) - Test and Adjust
/0-^^
MM Relief Valve (Line) - Test and Adjust
- ^ ^ Relief Valve (Swing) - Test and Adjust
Solenoid Valve (Swing Parking Brake) - Test
Control Valve (Boom Lowering) - Test and Adjust..
19
20
20
21
24
28
29
30
Pump Flow Measurement and Adjustment

Main Pump (Flow) - Test (Constant Horsepower Flow
Control)
34
Pump Control (Output Flow) - Adjust
40
Pump Control (Negative Flow) -Test
41
Pump Control (Negative Flow) - Adjust
48
Gear Pump (Pilot) - Test
49
Hydraulic Motor and Pump Performance Tests
Swing Motor - Test (Measurement of Case Drain
Oil)
53
Travel Motor - Test (Measurement of Case Drain
Oil)
54
Reference Specifications
Specifications
56
Index Section
Index
60
4
Hydraulic System

Section
Visual Inspection
SMCS Code: 5050-040

General Testing and Adjusting
information
A visual inspection of the system is the first step in

order to troubleshoot a problem. Shut off the engine
and lower all implements to the ground before
performing the visual inspection.
1. Check the oil level in the hydraulic tank. Slowly
loosen the fill/vent plug and release the pressure
before the fill/vent plug is removed.
SMCS Code: 5050
WARNING
Hydraulic oil pressure can remain in the hydraulic
systems after the engine and pump have been
stopped. Serious injury can be caused if this pressure is not released before any service is done on
the hydraulic systems. To prevent possible injury,
refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any
fitting, hose or component is loosened, tightened,
removed or adjusted.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide" for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
When possible, the work tool must always be lowered to the ground before service is started. When
it is necessary for the boom to be in the raised
position while tests or adjustments are done, be
sure that the boom, stick and work tool have correct support.
2. Remove the hydraulic filter elements. Inspect the

hydraulic filters for material that would give an
indication of damage to a component.
The swing lock (if equipped) must be engaged before service is started.
3. Inspect all lines and connections for damage

or leaks.
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.
4. Inspect control linkages for bent components,

broken components or damaged components.
The correct oil temperature, flow, and pressure are

necessary for correct operation. Pump output (oil
flow) is a function of engine speed (rpm) and valve
adjustment. Oil pressure is caused by resistance to
the flow of oil.
Visual checks and measurements are the first
steps during troubleshooting. Refer to Testing And
Adjusting, "Visual Inspection". Next, perform the
operational checks. Refer to Testing And Adjusting,
"Operational Checks". Finally, perform the required
tests and adjustments on the machine.
i01246594
Hydraulic System Pressure Release

SMCS Code: 4250-553-PX; 5050-553-PX
The release of hydraulic pressure in a hydraulic
circuit is required before service is performed to
that hydraulic circuit. Release the pressure in the
following hydraulic circuits before any hydraulic
lines are disconnected or removed from that
hydraulic circuit.
Boom hydraulic circuit
Stick hydraulic circuit
5
Hydraulic System
Bucket hydraulic circuit
Swing hydraulic circuit
Travel hydraulic circuit
Attachment hydraulic circuits (if equipped)
Pilot hydraulic circuit
Return hydraulic circuit
Note: Refer to the Disassembly and Assembly
Manual for additional information concerning service
of the components of specific hydraulic circuits.
Release Of Hydraulic Pressure

From A Single Hydraulic Circuit
WARNING
Personal injury can result from hydraulic oil pressure and hot oil.
system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic
system.
Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
products.
mandates.
Perform the following Steps in order to release the
hydraulic pressure from a single hydraulic circuit of
the main hydraulic system.
1. Position the machine on level ground.
Illustration 1
2. Fully retract the stick cylinder rod. Adjust the

position of the bucket so that the bucket is
parallel to the ground. Lower the boom until the
bucket is flat on the ground. Refer to Illustration
1.
3. Shut off the engine.
4. Turn the engine start switch to the ON position
without starting the engine.
5. Place the hydraulic activation control lever in the
UNLOCKED position.
6. Move only the joysticks or the pedals of the
hydraulic circuit that requires service to the FULL
STROKE positions. This will release the high
pressure only in that single hydraulic circuit.
This will also release any pressure that might be
present in the pilot hydraulic circuit.
Note: if the desired hydraulic circuit that requires
service requires the activation of a switch for
operation, activate the necessary switches for the
operation of the hydraulic circuit.
LOCKED position.
8. Turn the engine start switch to the OFF position.
9. Slowly loosen the filler plug on the hydraulic tank
and release the pressure from the hydraulic tank.
Leave the filler plug loose for a minimum of 45
seconds. This will release the pressure that may
be present in the return hydraulic circuit.
10. Tighten the filler plug on the hydraulic tank to
the specified torque.
11. The pressure in the single hydraulic circuit that
requires service is now released and lines and
components can be disconnected or removed
from that hydraulic circuit.
6
Hydraulic System
Release Of Hydraulic Pressure

From Multiple Hydraulic Circuits
WARNING
system.
Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the
filler cap is cool enough to touch with your bare
hand.
NOTICE
products.
mandates.
Perform the following Steps in order to release the
hydraulic pressure from multiple hydraulic circuits
of the main hydraulic system.
2. Fully retract the stick cylinder rod. Adjust the

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

Pressure - Purge
SMCS Code: 5070-542-AI
When the main pumps have been serviced or the
hydraulic oil has been replaced, remove the air
from the hydraulic system. Remove the air from the
hydraulic system in the following manner:
NOTICE
products.
mandates.
WARNING
system.
Make sure all of the work tools have been lowered
to the ground, and the oil is cool before removing
any components or lines. Remove the oil filler cap
only when the engine is stopped, and the filler cap
is cool enough to touch with your bare hand.
Illustration 3
Pump compartment
(1)
(2)
(3)
(4)
Connector
O-Ring seal
Case drain hose
Negative flow control hose
1. While the engine is stopped, disconnect hose

(3) from connector (1).
2. Remove connector (1) and O-Ring seal (2) from
the pump housing.
3. Fill the main pumps with oil.
4. Inspect O-Ring seal (2). If the seal is damaged,
replace the seal.
5. Install O-Ring seal (2) and connector (1) at the
pump housing.
6. Connect hose (3) to connector (1). Tighten hose
(3) to the specified torque.
NOTICE
To avoid system damage, make sure that the hydraulic
pump is properly filled with hydraulic oil before startup.
8. Place the engine at low idle position. Raise the
boom and hold the boom in this position.
9. Slowly loosen hose (4) until oil begins to flow
around the hose connection.
10. Tighten hose (4) to the specified torque.
11. Stop the engine and slowly lower the boom until
the bucket is on the ground. This pressurizes
the hydraulic tank.
8
Hydraulic System
Illustration 4
(5) Vent plug
12. Slowly loosen vent plug (5) until oil begins to

flow from the opening.
13. Tighten the vent plug to the specified torque.
9
Hydraulic System
Performance Tests
Table 2
320C L Machine Configuration
Operational Checks
Boom
Stick
Bucket
5.67 m
(18 feet 6 inches)
2.92 m
(9 feet 6 inches)
0.9 m3 (1.17 yd3)
SMCS Code: 5050-535

The operational checks can be used to find
leakage in the system and components that are not
functioning correctly. The speed of rod movement
or the torque on a motor can be used to check the
condition of the cylinders, motors and the pumps.
Engine Performance - Test

(Engine Speed)
SMCS Code: 1000-081
Perform the following operational checks in order

to troubleshoot problems concerning the hydraulic
circuits and components on the machine.
Testing and Adjusting, "Engine Performance Test"
Testing and Adjusting, "Travel On Level Ground Test"
Table 3
Required Tools
Part
Number
Description
Qty
9U-7400
Multitach Tool Group
Testing and Adjusting, "Travel On Level Ground

- Test (Optional Test)"
2. Stop the engine.
Testing and Adjusting, "Machine Drift On A Slope

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

engine.
Testing and Adjusting, "Swing Speed And

Overswing On Level Ground - Check"
Testing and Adjusting, "Swing Speed And Swing

Drift On A Slope - Check"
Testing and Adjusting, "Cylinder Drift - Check
(Empty Bucket)"
Testing and Adjusting, "Cylinder Drift - Check
(Loaded Bucket)"
Testing and Adjusting, "Cylinder Speed - Check"
The specifications that are listed in tables for the
operational checks are calculated average values.
The values will vary due to the configuration of the
machine and engine speed. Table 1 and Table 2
contain the machine configurations that were used
in order to obtain these specifications.
Reference: Refer to Testing and Adjusting, "Engine
Performance - Test" for the specifications for engine
speed.
Table 1
320C Machine Configuration

Boom
Stick
Bucket
5.67 m
(18 feet 6 inches)
2.92 m
(9 feet 6 inches)
0.8 m3 (1.04 yd3)
5. Increase the hydraulic oil temperature to

55 5C (131 9F).
6. Read the engine speed display (rpm) on the
multitach. Refer to Table 4 for the specifications
for engine speed at the desired engine operation.
10
Hydraulic System
Table 5
Table 4
Required Tools
Specifications
Item
New
Rebuild
1860 5 0 rpm(1)
1660 to
1910
rpm(1)
1970 5 0 rprnP)
1770 to
2020
rpm (3)
900 50 rpm
900
100 rpm
No load high idle(2)
No load low idle

Maximum speed
with load (4)
No load speed(6)
Service
Limit
1720
rpm(5)
1670
rpm(5)
1300 80 rpm
Part
Number
Description
Qty
Stopwatch
1620
rpm(5)
1300
100 rpm
(1) AEC switch in the OFF position

(2) Three seconds after the engine speed dial was placed at
position "10"
(3) Engine rpm within three seconds after the engine speed dial
was placed at position "10"
(4) Pressure is relieved from both pumps (stall condition).
(5) Minimum rpm
(6) AEC switch in the ON position
Note: A New specification is the performance that

can be expected for a new machine. A Rebuild
specification is the performance that can be
expected after rebuilding the components of a
system. Performance beyond the Service Limit is an
indication of these problems: improper maintenance
or adjustment, component wear, and failure.

(Optional Test)
SMCS Code: 4351-081
Note: When the procedure for the Travel Test On
Level Ground cannot be performed, this test may
be used as a substitute.
Note: The engine speed and/or the machine
configuration that is used during this test can
affect the results of this test. Refer to Testing and
Adjusting, "Engine Performance - Test" for the
engine speed that was used for this test. Refer to
Testing and Adjusting, "Operational Checks" for the
machine configurations that were used for this test.
Note: The relief valve pressure settings must be
set to the relief valve pressure specification before
performing this operational check. Refer to Testing
and Adjusting "Specifications".
Illustration 5

55 5C (131 9F).
4. Raise a track off the ground. Refer to Illustration
5.
5. Put a mark on a shoe of the raised track.
6. Place the machine controls at the following
settings: Engine speed dial "10" and AEC switch
OFF.
7. Place the travel speed control switch in HIGH
position.
8. Move the travel lever of the raised track to full
travel position.
9. Measure the time that is required for the raised
track to make three complete revolutions.
Measure the time that is required in each
direction.
10. Place the travel speed control switch in the LOW
position and repeat Steps 8 through 9.
11
Hydraulic System
Table 6
320C Time For Three Revolutions (time in seconds)

New
Rebuild
Service
Limit
17.0 or
less
18.0 or
less
19.0 or
less
27.5 or
less
28.5 or
less
30.5 or
less
Travel Speed
Forward
HIGH
Reverse
LOW
Forward
Reverse
Table 7
320C L Time For Three Revolutions (time in seconds)
HIGH
Forward
Reverse
LOW
Forward
Reverse
Illustration 6
New
Rebuild
Service
Limit
(A) Preliminary run 5 m (16.4 ft)
18.5 or
less
19.6 or
less
20.7 or
less
(C) Bucket height 0.5 to 1 m (1.6 to 3.3 ft)
30.0 or
less
31.0 or
less
33.2 or
less
1. Travel distance must be at least 25 m (82 ft)

long. Travel test ground must be hard and as
level as possible.
Travel Speed
(B) Travel distance 20 m (65.6 ft)
2. Draw a 25 m (82 ft) straight line on travel test

ground as a reference line.

SMCS Code: 4351-081
and Adjusting, "Specifications".
Table 8

settings: Engine speed dial "10" and AEC switch
OFF.
55 5C (131 9F).
6. The bucket should be empty.
7. Position the machine so that one track is parallel
with the reference line. Position the machine for
the travel test. Refer to Illustration 6.
8. Place the travel speed control switch in HIGH
position.
9. Move the machine by operating both travel
levers at the same time.
Required Tools
Part
Number
Description
Qty
5P-3277
Measuring Tape
Stopwatch
10. The first 5 m (16.4 ft) are for a preliminary run.

Measure the travel time that is required to travel
the remaining 20 m (65.6 ft). Measure the time
that is required in each direction.
11. Measure the travel deviation from the reference
line.
12. Place the travel speed control switch on the
LOW position and repeat Steps 9 through 11.
12
Hydraulic System
Table 11
Table 9
Travel Time (time in seconds)
New
Rebuild
Service
Limit
14.0 or
less
15.0 or
less
16.0 or
less
22.0 or
less
23.5 or
less
25.0 or
less
Travel Speed
HIGH
Forward
Reverse
LOW
Forward
Reverse
Required Tools
Part
Number
Description
Qty
Stopwatch
Scale150 mm (6 inch)
Note: The following table represents the travel

deviation (distance) from the reference line.
Table 10
Travel Deviation
mm (inch)
New
Rebuild
Service
Limit
800
(31.5) or
less
1200
(47.2) or
less
1500
(59.1) or
less
800
(31.5) or
less
1200
(47.2) or
less
1500
(59.1) or
less
Travel Speed
Forward
HIGH
Reverse
Forward
LOW
Reverse
Illustration 7
1. Place the machine on a slope of 12 degrees. The

surface of the slope must be hard and smooth.
2. Position the implements, as shown. Refer to
Illustration 7.
Machine Drift on a Slope Check
SMCS Code: 4095-535

Measuring the amount of drift of the machine on a
slope will determine if there is a need to check the
travel brake.
Illustration 8
4. To indicate the machine's relative position to the

slope, put a mark on both the track and the track
roller frame. Refer to Illustration 8.
5. Stop the engine.
6. Measure the machine movement on the slope
after three minutes.
13
Hydraulic System
Table 12
Drift mm (inch)
New
Rebuild
Service Limit
Swing Speed and Overswing

on Level Ground - Check
SMCS Code: 5058-535-ZW
Measuring the swing speed and the overswing of
the machine will determine if there is a need to
check the swing motor or the anti-reaction valve.
The fine swing control switch (if equipped) must
be in the OFF position.
Table 13
Required Tools
Part
Number
Description
Qty
5P-3277
Measuring Tape
Stopwatch
Illustration 9
1. Position the machine on level ground. Refer to

Illustration 9.
2. Stop the engine.
Illustration 10
(A) Upper frame
(B) Undercarriage frame
(C) Marking
3. To indicate the relationship of the two positions,

put a mark (C) on the inner race and the outer
race of the swing bearing. The mark will be used
as a target to stop the swing operation. Refer
to Illustration 10.
5. Move the swing joystick in either direction until
the machine completes a 180 degree swing
operation away from the target.
6. Move the swing joystick in either direction until
the machine completes a 180 degree swing
operation toward the target. Return the swing
joystick to the NEUTRAL position at the target.
7. Measure the amount of overswing by measuring
the distance between the marks on the swing
bearing. Refer to Illustration 10.
Note: Use a point that is visible from the operator
seat as a reference point for the target.
14
Hydraulic System
Table 14
Overswing
Item
New
Rebuild
Service
Limit
Right Swing
1100 mm
(43.3 inch)
or less
1200 mm
(47.2 inch)
or less
1400 mm
(55.1 inch)
or less
Left Swing
8. Move the swing joystick in each direction and

measure the time that is required to complete a
180 degree swing operation.
Table 15
Illustration 11
Swing Time
Item
New
Rebuild
Service
Limit
Right Swing
4.2 seconds
or less
4.6 seconds
or less
5.2 seconds
or less
Left Swing
g00298078
1. Complete the following steps in order to measure

the swing speed on a slope.
a. The bucket should be empty.
b. Position the machine on a slope of 12
degrees. Refer to Illustration 11.
i01586858
Swing Speed and Swing Drift

on a Slope - Check
c. Position the implements at maximum reach

and close the bucket. Position the bucket
above the ground so that the bucket will not
come in contact with any obstacles.

Measuring the swing speed on a slope will
determine if there is a need to check the swing
motor and the anti-reaction valve. Measuring the
swing drift on a slope will determine if there is a
need to check the swing parking brake.
Illustration 12

g00298079
d. Position the upper structure at position

(A). The upper structure should be at a 90
degree angle to the lower structure. Refer to
Illustration 12.
Table 16
Required Tools
Part
Number
Description
Qty
5P-3277
Measuring Tape
Stopwatch
e. Measure the time that is required to swing the

upper structure from position (A) to position
(B).
f. Position the upper structure at position (C).
The upper structure should be at a 90 degree
angle to the lower structure.
15
Hydraulic System
g. Measure the time that is required to swing the
upper structure from position (C) to position
(B).
e. Start the engine.
Table 17
Swing Time (seconds)

Item
Right Swing
d. Leave the machine in this position for three

minutes. Measure the swing drift on the
circumference of the swing bearing.
New
Rebuild
Service
Limit
5.2 or less
5.7 or less
6.5 or less
Left Swing
2. Complete the following steps in order to measure
the swing drift on a slope.
f. Position the upper structure at position

(C). The upper structure should be at a 90
Illustration 13.
g. Repeat Steps 2.b through 2.d.
Table 18
Swing Drift mm (inch)

Item
Right Swing
New
Rebuild
Service
Limit
Left Swing
Cylinder Drift - Check

(Loaded Bucket)
SMCS Code: 7562-535-D9
Illustration 13
a. Position the upper structure at position

(A). The upper structure should be at a 90
Illustration 13.

Illustration 14
(A) Upper frame
(B) Undercarriage frame
(C) Marking
b. To indicate the relationship of the two

positions, put a mark (C) on the inner race
and the outer race of the swing bearing. Refer
to Illustration 14.
c. Stop the engine.
16
Hydraulic System
Table 20
Table 19
Required Tools
Cylinder Drift (Loaded Bucket)
Part
Number
Description
Qty
New Boom
Cylinder
New Stick
Cylinder
New Bucket
Cylinder
5P-3277
Measuring Tape
Stopwatch
6.0 mm
(0.24 inch) or
less
12.0 mm
(0.47 inch) or
less
18.0 mm
(0.71 inch) or
less
i01572461
Cylinder Drift - Check

(Empty Bucket)
SMCS Code: 7562-535-D9
Illustration 15

Illustration 15.
2. Load the bucket.
Weight of bucket load
320C
320C L

Table 21
1050 kg (2310 lb)

1200 kg (2650 lb)
3. Raise the boom until the top stick pin is the same
height as the boom foot pin.
Required Tools
Part
Number
Description
Qty
5P-3277
Measuring Tape
Stopwatch
4. Fully extend the bucket cylinder.

5. Fully retract the stick cylinder.
6. Extend the stick cylinder rod 70 mm (2.8 inch)
from the fully retracted position.
7. Measure each cylinder's length from cylinder pin
to cylinder pin.
8. Stop the engine.
9. Leave the machine in this position for three
minutes. Measure each cylinder's length from
cylinder pin to cylinder pin for drift.
Illustration 16

Illustration 16.
2. Empty the bucket.
17
Hydraulic System
3. Raise the boom until the top stick pin is the same
height as the boom foot pin.
4. Fully extend the bucket cylinder.
5. Fully retract the stick cylinder.
6. Extend the stick cylinder rod 70 mm (2.8 inch)
from the fully retracted position.
7. Measure each cylinder's length from cylinder pin
to cylinder pin.
8. Stop the engine.
9. Leave the machine in this position for five
minutes. Measure each cylinder's length from
cylinder pin to cylinder pin for drift.
Table 22
Illustration 17
(A) Extension test
(B) Retraction test
a. Place the machine on level ground.
Cylinder Drift (Empty Bucket)

Item
New
Rebuild
Service
Limit
Boom
Cylinder
6.0 mm
(0.24 inch)
or less
12.0 mm
(0.47 inch)
or less
24.0 mm
(0.94 inch)
or less
Stick
Cylinder
10.0 mm
(0.39 inch)
or less
15.0 mm
(0.59 inch)
or less
25.0 mm
( 0.98 inch)
or less
Bucket
Cylinder
10.0 mm
( 0.39 inch)
or less
15.0 mm
(0.59 inch)
or less
25.0 mm
( 0.98 inch)
or less
b. The bucket should be empty.

c. Fully retract the bucket cylinder and the stick
cylinder.
d. Position the bucket on the ground. With a
stopwatch, measure the time that is required
to fully extend the boom cylinders.
e. Position the boom cylinders at full extension.
With a stopwatch, measure the time that is
required for the bucket to come in contact
with the ground.
f. Refer to the specifications in Table 23 for the
operating speed of the boom cylinders.

SMCS Code: 5456-535-VF; 5458-535-VF
2. Perform the following steps in order to test the

operating speed of the stick cylinder.

operating speed of the boom cylinders.
Illustration 18
(A) Extension test
(B) Retraction test

18
Hydraulic System
c. Position the upper surface of the boom
parallel to the ground.
Table 23
Cylinder Operating Speed (seconds)
d. Fully extend the bucket cylinder.

e. Retract the stick cylinder. With a stopwatch,
measure the time that is required to fully
extend the stick cylinder.
f. Extend the stick cylinder. With a stopwatch,
measure the time that is required to fully
retract the stick cylinder.
g. Refer to the specifications in Table 23 for the
operating speed of the stick cylinder.
operating speed of the bucket cylinder.
Illustration 19
(A) Extension test
(B) Retraction test

c. Position the upper surface of the boom
parallel to the ground.
d. Position the stick so that the stick is
perpendicular to the ground.
e. Fully retract the bucket cylinder.
f. With a stopwatch, measure the time that is
required to fully extend the bucket cylinder.
g. Position the bucket cylinder at full extension.
With a stopwatch, measure the time that is
required to fully retract the bucket cylinder.
h. Refer to the specifications in Table 23 for the
operating speed of the bucket cylinder.
New
Rebuild
Service
Limit
Extension
2.8 0.5
3.2(1)
3.6(1)
Retraction
1.9 0.5
2.2(1)
2.4 (1)
Extension
3.2 0.5
3.7(1)
4.2 (1)
Retraction
2.4 0.5
2.6(1)
3.0(1)
Extension
3.3 0.5
3.8(1)
4.3 (1)
Retraction
1.8 0.5
2.1(1)
2.3(1)
Item
Boom
Stick
Bucket
(1)
(1) M a x i m u m
Maximum
19
Hydraulic System
Hydraulic Pressure
Adjustments
(Table 24, contd)
Required Tools
Part
Number
Required Tools
Description
Qty
6K-6307
O-Ring Seal
18
7M-8485
O-Ring Seal
SMCS Code: 0701; 0738; 0770; 0774; 0775; 0784;

7320
1P-3703
Rectangular Seal
5P-0201
Hose
S/N: ANB1-Up
5P-1010
Sleeve
S/N: BCB1-Up
5P-3277
Measuring Tape
8T-0470
Thermometer Group
8T-0855
Pressure Gauge
8T-0856
Pressure Gauge
S/N: BDB1-Up
S/N: AMC1-Up
S/N: BBC1-Up
8T-0861
Pressure Gauge
S/N: BDC1-Up
8T-4184
Bolt
S/N: ALF1-Up
8T-4223
Hard Washer
S/N: BEF1-Up
8T-5082
Union
S/N: AKH1-Up
8T-8902
Elbow
S/N: BER1-Up
1U-8292
Adapter
1U-8303
Fitting
9U-7335
Blocking Cover
9U-7400
6V-0400
Half Flange
177-7860
Hose
6V-3965
Nipple Assembly
6V-3989
Unvalved Nipple
6V-4143
Coupler Assembly
10
6V-8397
O-Ring Seal
6V-8398
O-Ring Seal
6V-8716
Seal Connector
6V-9508
Face Seal Plug
6V-9509
Face Seal Plug
6V-9829
Cap
6V-9830
Cap
6V-9832
Cap
6V-9840
Swivel Tee
6V-9854
Swivel Elbow
S/N: BPR1-Up
S/N: BRX1-Up
Table 24
Required Tools
Part
Number
Description
Qty
Container for measuring
Remote drain hose with

inside diameter of 20 mm
(0.78 inch)
Scale 150 mm (6 inch)
Stopwatch
FT-2542
Track block assembly
4C-6481
Coupler Assembly
4C-6482
Nipple Assembly
4C-8767
Coupling
4C-9910
Portable Hydraulic Tester

(Flow Meter)
8C-9026
Adapter
4I-6140
Coupling
4I-6141
Coupling
3J-1907
O-Ring Seal
5K-9090
O-Ring Seal
16
(continued)
20
Hydraulic System
Relief Valve (Pilot) - Test and

Adjust
SMCS Code: 5072-025; 5072-081
1. Place the machine on level ground.
2. Stop the engine.
3. Release the pressure in the hydraulic system.
Refer to Testing and Adjusting, "Hydraulic
System Pressure - Release".
11. Turn setscrew (29) until the pressure gauge

reading at pressure tap (30) is 4100 200 kPa
(595 29 psi).
Note: Turning setscrew (29) clockwise increases the
pressure. Turning setscrew (29) counterclockwise
decreases the pressure.
Note: Always make final pressure adjustments on
pressure rise.
12. Tighten locknut (28) to a torque of 49
(36 4 lb ft).
4.9 N-m
Note: Normal operation of the engine and pumps

are necessary for the pressure adjustment. If the
results of the pressure adjustments are not correct,
then the engine and the pump characteristic curve
needs to be checked.
Relief Valve (Main) - Test and

Adjust
SMCS Code: 5069-025; 5069-081
Illustration 20
Pilot oil manifold compartment
(28)
(29)
(30)
(31)
Locknut
Setscrew
Pressure tap
Pilot filter
1. Position the machine on level ground and stop

the engine.
Refer to Testing And Adjusting, "Hydraulic
4. Connect a 6000 kPa (870 psi) pressure gauge to

pressure tap (30).
settings: engine speed dial "10" and AEC switch
OFF Refer to Testing and Adjusting, "Engine
Performance - Test" for engine rpm settings.
55 5C (131 9F).
8. Check the pilot relief valve setting at pressure
tap (30).
9. The pilot relief valve setting should be
4100 200 kPa (595 29 psi). If the pilot relief
valve setting is not within the specification, adjust
the pilot relief valve.
10. In order to adjust the pilot relief valve, loosen
locknut (28).
Illustration 21
Pump compartment
(1) Pressure tap (right pump delivery pressure)
(2) Pressure tap (left pump delivery pressure)
(3) Pressure tap (power shift pressure)
3. Attach a 60000 kPa (8700 psi) pressure gauge

to pressure tap (1).
>
21
Hydraulic System
OFF. Refer to Testing and Adjusting, "Engine
55 5C (131 9F).
1. The main relief valve pressure setting should be

34300 490 kPa (4950 72 psi). If the main
relief valve is not within the specification, adjust
the main relief valve pressure setting to the
correct pressure specification before performing
Step 2. Refer to Testing and Adjusting, "Relief
Valve (Main) - Test and Adjust".
7. Open the bucket until the bucket cylinder rod

is at the full retraction.
8. Check the main relief valve pressure setting at
pressure tap (1).
9. Return the joystick for the bucket to the
NEUTRAL position.
10. The main relief valve pressure setting should
be 34300 490 kPa (4950 72 psi). If the
main relief valve pressure setting is not within
the specification, adjust the main relief valve
pressure setting.
Top of main control valve
(4) Adjustment screw
(5) Locknut
(6) Main relief valve
2. Loosen locknut (5) and turn adjustment screw (4)

clockwise for one half turn. Tighten locknut (5)
to the specified torque.
pressure rise.

(5) Locknut
Relief Valve (Crossover) - Test

and Adjust
SMCS Code: 5069-036
11. In order to adjust the main relief valve, loosen

locknut (5) and turn adjustment screw (4) until
the pressure gauge reading at pressure tap (1)
is 34300 490 kPa (4950 72 psi).
Note: Turning adjustment screw (4) clockwise
increases the pressure. Turning adjustment screw
(4) counterclockwise decreases the pressure.
Note: A temporary setting of the main relief valve is

required before travel crossover relief valves can be
tested. Refer to Testing And Adjusting, "Relief Valve
(Main) - Test and Adjust".
2. Stop the engine.

pressure rise.
12.Tighten locknut (5) to a torque of 50 10 N.m
(37 7 lb ft).
Temporary Setting of the Main

Relief Valve
Note: A temporary setting of the main relief valve is
required before any line relief valve can be adjusted.
22
Hydraulic System
OFF. Refer to Testing And Adjusting, "Engine
55 5C (131 9F).
Pump compartment

pressure tap (3).
4. Connect a 60000 kPa (8700 psi) pressure gauge
to pressure tap (1). Use this pressure gauge
to monitor the crossover relief valve pressure
setting of the right travel motor.
to pressure tap (2). Use this pressure gauge
to monitor the crossover relief valve pressure
setting of the left travel motor.
Illustration 26
Monitor
(A) Message display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Set key
(I) OK key
(J) Menu key
Illustration 25
10. Start Service Mode and input a fixed power shift

pressure of 2900 kPa (420 psi).
Sprocket (left track)

(16) Sprocket
(17) FT-2547 Track block assembly
6. Place track block assembly (17) in sprocket

(16) in order to block forward left travel. Refer
to Illustration 25.
a. Press menu key (J).

Note: If more than thirty seconds pass between
pushing the keys on the keypad, the menu mode
will be cancelled and the previous display will be
restored to message display (A).
b. Press down key (E) in order to highlight
the menu item "SERVICE OPTIONS" on the
message display. Press OK key (I).
23
Hydraulic System
c. Input the password "FFF2". Press left key (D)
or right key (F) in order to change the position
of the flashing character. Press up key (C) or
press down key (E) in order to change the
value of the flashing character. Press OK key
(I) after the correct password is displayed.
d. Press down key (E) once in order to highlight
the second line on the message display.
e. Press right key (F) repeatedly until "DEVICE
TEST" appears on the message display.
f. Press down key (E) in order to move down
one line on the message display.
g. Press right key (F) until the "PS PRV - FIXED"
appears on the message display.
h. Press down key (E).
i. Press OK key (I). The display on line 4 of
the message display will now change to a
numeric value. These characters represent
the power shift pressure (kPa).
j. Press left key (D) or right key (F) in order to
increase or decrease the numeric value that
is displayed on line 4 of the message display.
Pressing left key (D) one time decreases
the power shift pressure 10 kPa (1.5 psi).
Pressing right key (F) one time increases the
power shift pressure 10 kPa (1.5 psi).
Note: The value for power shift pressure on the
monitor may not always match the pressure reading
on the pressure gauge. Adjust the value on the
monitor until the desired power shift pressure is
attained on the pressure gauge that is connected to
the pressure tap for power shift pressure. The actual
power shift pressure must be 2900 kPa (420 psi)
on the pressure gauge.
k. Press up key (C). "SUCCESS" should appear
on the message display.
Note: To prevent a change in power shift pressure
during the relief valve adjustment, do not turn the
engine start switch to the OFF position.
Note: Refer to Service Manual, "Engine And Pump
Electronic Control System' for additional information
on Service Mode.
Illustration 27
Travel brake valve (left side)
(18)
(19)
(20)
(21)
(22)
(23)
Locknut
Adjustment screw
Crossover relief valve (forward left travel)
Crossover relief valve (reverse left travel)
Locknut
Adjustment screw
11. Slowly move the left travel control lever to full

FORWARD position and check the pressure
gauge reading at pressure tap (2). The pressure
setting of crossover relief valve (20) should be
36800 1470 kPa (5350 215 psi).
12. Return the left travel control lever to the
NEUTRAL position.
13. In order to adjust crossover relief valve (20),
loosen locknut (18) and turn adjustment screw
(19) until the pressure gauge reading at pressure
tap (2) is 36800 1470 kPa (5350 215 psi).
Note: Always make final pressure adjustment on
pressure rise.
14. Tighten locknut (18) to a torque of 130 13 N-m
(95 10 lb ft).
pressure rise.
15. Place track block assembly (17) in sprocket (16)
in order to block reverse left travel.
16. Slowly move the left travel lever to full REVEF5SE
position and check the pressure gauge
reading at pressure tap (2). The pressure
setting of crossover relief valve (21) should be
36800 1470 kPa (5350 2 1 5 psi).
17.Re*um the left travel control lever to Hie
NEUTRAL position.
24
Hydraulic System
18. In order to adjust crossover relief valve (21),
loosen locknut (22) and turn adjustment screw
(23) until the pressure gauge reading at pressure
tap (2) is 36800 1470 kPa (5350 215 psi).
pressure rise.
19.Tighten locknut (22) to a torque of 130 13 N.m
(95 10 lb ft).
Illustration 28

pressure rise.
Pump compartment
20. After relief valve adjustments, cancel Service

Mode.

2 1 . Return the main relief valve pressure to the

specified setting after crossover relief valve
pressure setting is attained.
In order to adjust the crossover relief valves on the
right travel motor, place stopper (17) in the sprocket
for right travel. Use the pressure gauge at pressure
tap (1) in order to monitor the crossover relief valve
pressure settings for the right travel motor. Adjust
the crossover relief valves on the right travel motor
in the same manner as the adjustment for the left
travel motor.
Relief Valve (Line) - Test and

Adjust
SMCS Code: 5117-025-L9; 5117-081-L9
Note: Adjustment procedures must be performed
before a test and adjustment of any line relief valve
pressure setting is attempted. A temporary setting
of the main relief valve pressure is required before
any line relief valve pressure setting is adjusted.
Refer to the adjustment procedures in Testing And
Adjusting, "Relief Valve (Main) - Test and Adjust".
Test
2. Stop the engine.

pressure tap (3). This is used to monitor power
shift pressure.
settings: engine speed dial 10 and AEC switch
55 5C (131 9F).
25
Hydraulic System
Illustration 29
Monitor
(A) Message display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Set key
(I) OK key
(J) Menu key

AIII be cancelled and the previous display will be

during the relief valve adjustment, do not turn the
engine start switch to the OFF position.
Electronic Control System" for additional information
on Service Mode.
11. The pressure setting for both the head end and
the rod end for each cylinder is 36800 1470 kPa
(5350 215 psi).
26
Hydraulic System
Illustration 30
Illustration 32
Main control valves (front view)
Main control valve (bottom view)
(7) Line relief valve (boom cylinder rod end)

(8) Line relief valve (bucket cylinder head end)
(9) Line relief valve (stick cylinder head end)
(12) Line relief valve (stick cylinder rod end)

(13) Stick drift reduction valve
The following line relief valves are located on top

of the main control valves: boom cylinder rod end,
bucket cylinder head end, and stick cylinder head
end. The line relief valve for the bucket cylinder rod
end is located under the main control valves and
opposite the line relief valve for bucket cylinder
head end (8).
The line relief valve (stick cylinder head end) (12) is

located on stick drift reduction valve (13).
Illustration 33
Line relief valve (typical example)
(14) Locknut
Illustration 31
Main control valve (bottom view)
(10) Boom drift reduction valve
(11) Line relief valve (boom cylinder head end)
The line relief valve (boom cylinder head end) (11)

is located on boom drift reduction valve (10).
Note: After relief valve adjustments, cancel Service

Mode.
Note: Return the main relief valve pressure to the
specified setting after testing and adjusting any line
relief valve. Refer to Testing And Adjusting, "Relief
Valve (Main) - Test and Adjust" for the main relief
valve pressure setting.
Adjustment (Stick Cylinder)

1. To adjust the line relief valve pressure setting of
the stick cylinder rod end, move the joystick for
the stick until the stick is at the full STICK OUT
position (full retraction of stick cylinder). Hold the
joystick for the stick in this position.
27
Hydraulic System
2. Check the pressure in the stick cylinder rod end
on the pressure gauge at pressure tap (2).
3. Return the joystick for the stick to the NEUTRAL
position.
4. Loosen locknut (14) on the stick line relief
valve. Turn adjustment screw (15) until the
pressure gauge reading at pressure tap (2) is
36800 1470 kPa (5350 215 psi).

the bucket cylinder rod end, move the joystick for
the bucket until the bucket is at the full BUCKET
OPEN position (full retraction of bucket cylinder).
Hold the joystick for the bucket in this position.
6. Check the pressure in the bucket cylinder rod
end on the pressure gauge at pressure tap (1).
NEUTRAL position.

the stick cylinder head end, move the joystick
for the stick until the stick is at the full STICK IN
position (full extension of stick cylinder). Hold the
joystick for the stick in this position.
8. Loosen locknut (14) on the bucket line relief

36800 1470 kPa (5350 215 psi).
6. Check the pressure in the stick cylinder head

9. After completion of line relief valve adjustment,

tighten locknut (14).
7. Return the joystick for the stick to the NEUTRAL

position.

8. Loosen locknut (14) on the stick line relief

36800 1470 kPa (5350 215 psi).
9. After completion of line relief valve adjustment,
tighten locknut (14).

pressure rise.
Adjustment (Boom Cylinders)

the boom cylinder head end, move the joystick
for the boom until the boom is at the full BOOM
RAISE position (full extension of boom cylinders).
Hold the joystick for the boom in this position.

pressure rise.
2. Check the pressure in the boom cylinder head

Adjustment (Bucket Cylinder)
3. Return the joystick for the boom to the NEUTRAL

position.
1. To adjust the line relief valve pressure setting

of the bucket cylinder head end, move the
joystick for the bucket until the bucket is at the
full BUCKET CLOSE position (full extension of
bucket cylinder). Hold the joystick for the bucket
in this position.
4. Loosen locknut (14) on the boom line relief

36800 1470 kPa (5350 215 psi).
2. Check the pressure in the bucket cylinder head

Note: In order to adjust the line relief valve pressure

setting for the boom cylinder rod end, a temporary
adjustment of the line relief valve for the bucket
cylinder rod end must be performed.

NEUTRAL position.
4. Loosen locknut (14) on the bucket line relief
36800 1470 kPa (5350 215 psi).
5. Loosen locknut (14) on the line relief valve for the

BUCKET OPEN function. Turn adjustment screw
(15) by one half turn in a clockwise direction.
Tighten locknut (14) on the line relief valve for
the bucket cylinder.
28
Hydraulic System
6. Move the joystick for the bucket until the
bucket is at the full BUCKET OPEN position
(full retraction of the bucket cylinder). Hold the
joystick for the bucket in this position. At the
same time, move the joystick for the boom until
the boom is at the full BOOM DOWN position (full
retraction of boom cylinders). Hold the joystick
for the boom in this position.
7. Check the pressure in the boom cylinder rod end
on the pressure gauge at pressure tap (1).
position.
9. Loosen locknut (14) on the boom line relief
36800 1470 kPa (5350 215 psi).
10. Tighten locknut (14) on the boom line relief valve.
Illustration 34
900666193
Pump compartment


pressure rise.
11. After completion of line relief valve adjustment
for the boom cylinders, return the line relief valve
pressure setting of the bucket to the specified
pressure setting.
Note: If an appropriate location is not available
to fully extend the boom cylinders, exchange the
functions of the boom line relief valves. Remove the
line relief valve for the boom cylinder head end and
the line relief valve for the boom cylinder rod end
from the main control valve. Exchange the location
in the main relief valve of the line relief valves.
Adjust the pressure of the boom line relief valve that
is now attached in the head end. After completion
of line relief valve adjustment, return the respective
line relief valves to the original locations.
Illustration 35
900668854
Pilot oil manifold

(28) Connector
(29) Swing parking brake solenoid valve
5. Disconnect connector (28) from swing parking

brake solenoid valve (29).
i01586888
Relief Valve (Swing) - Test and

Adjust
SMCS Code: 5454-036
2. Stop the engine.

OFF.
Reference: Refer to Testing And Adjusting,
"Engine Performance - Test" for engine rpm
settings.
8. Move the swing joystick slowly and ensure that
the swing parking brake is operating properly.
29
Hydraulic System
17. In order to adjust the swing relief valve, loosen
locknut (27). Turn adjustment plug (26) until the
26000 980 kPa (3750 140 psi).
Note: Turning adjustment plug (26) clockwise
increases the pressure. Turning adjustment plug
pressure rise.
18.Tighten locknut (27) to a torque of 117 10 N-m
(85 7 lb ft).
Illustration 36
Swing motor
(22)
(23)
(24)
(25)
(26)
(27)
Adjustment plug
Locknut
Relief valve (left swing)
Relief valve (right swing)
Adjustment plug
Locknut
9. Slowly move the swing joystick for a full SWING

RIGHT operation and check the pressure for
relief valve (25) at pressure tap (2).
10. Return the swing joystick to the NEUTRAL
position.
11. The pressure setting of the swing relief valve
is 26000 980 kPa (3750 140 psi). If the
pressure reading at pressure tap (2) is not within
the specification, adjust the swing relief valve.
12. In order to adjust the swing relief valve, loosen
locknut (23). Turn adjustment plug (22) until the
26000 980 kPa (3750 140 psi).
Note: Turning adjustment plug (22) clockwise
increases the pressure. Turning adjustment plug
19. After completing the test and/or the adjustment

procedures for the swing relief valves, stop the
engine.
21. Connect connector (28) to the solenoid valve for
swing parking brake (29).
101586890
Solenoid Valve (Swing Parking

Brake) - Test
SMCS Code: 5483-081-OD
NOTICE

pressure rise.

products.

(85 7 lb ft).

mandates.
14. Slowly move the swing joystick for a full SWING

LEFT operation and check the pressure for relief
valve (24) at pressure tap (2).
15. Return the swing joystick to the NEUTRAL
position.
16. The pressure setting of the swing relief valve
is 26000 980 kPa (3750 140 psi). If the
pressure reading at pressure tap (2) is not within
the specification, adjust the swing relief valve.

2. Stop the engine.
30
Hydraulic System
UNLOCKED position.
13. Check the pressure gauge reading at pressure
gauge (1). When all of the joysticks are in the
NEUTRAL position, the swing parking brake
solenoid valve is not energized and the swing
parking brake is engaged. The pressure gauge
reading should be 0.0 kPa (0.0 psi).
14. Slowly move the swing joystick away from the
NEUTRAL position and check the pressure on
pressure gauge (1). The swing parking brake
solenoid valve should now be energized and the
swing parking brake should be released. The
pressure gauge reading should be equal to the
pilot system pressure.
Control Valve (Boom Lowering)

- Test and Adjust
SMCS Code: 5147-025-BM; 5147-081-BM
Two preliminary temporary adjustment procedures
must be performed:
Illustration 37
(1) 8T-0856 Pressure Gauge
(2) 6V-3989 Fitting
(3) 6V-4143 Coupler
(4) 177-7860 Hose Assembly
(5) Swing motor
(6) Connector at rear of swing motor
(7)6V-8397 0-RingSeal
(8) 6V-3965 Fitting Assembly
(9) 3J -1907 O-Fting Seal
(10) Pilot hose
(11) 8T-8902 Tee
4. Disconnect pilot hose (10) from connector (6) at

the rear of swing motor (5).
5. Install seal (7) and tee (11) to connector (6).
6. Install seal (7) and pilot hose (10) to tee (11).
7. Install seal (9) and fitting (8) to tee (11).
8. Assemble and install the test hose and gauge to
fitting (8).
settings : engine speed dial "10" and AEC switch
55 5C (131 9F).
1. A temporary setting of the main relief valve

pressure is required.
2. A temporary line relief setting of the head end of
the boom cylinder is required.
Four relief valves are involved in this procedure:
main relief valve
head end of the boom line relief valve
boom lowering control valve of the right cylinder
boom lowering control valve of the left cylinder
Note: A New specification is the performance
that can be expected for a new machine. A
Rebuild specification is the performance that can
be expected after rebuilding the components
of a system. Performance beyond Service Limit
specifications is an indication of these problems:
improper adjustment, wear, damage of relief valves,
and damage of pumps.
31
Hydraulic System
Table 25
Specifications
Relief Valve
(A) Main relief valve

(B) Boom cylinder line (head end)
(C) Boom lowering control valve
Torque
for
Locknut
New
Rebuild
Service Limit
34300 490 kPa

(4950 72 psi)
34300 490 kPa

(4950 72 psi)
32340 to 34790 kPa

(4700 to 5050 psi)
50 10
Nm (37
7 lb ft)
36800 + 1470 kPa

(5350 215 psi)
36800 1470 kPa

(5350 215 psi)
33850 to 38270 kPa

(4920 to 5565 psi)
20 2
Nm (14
4 lb ft)
Table 26
Required Tools
Part
Number
Description
Qty
9U-7400
8T-0470
Thermometer group
Table 27
Relief Valves
Pressure change With

One Turn Of Adjustment
Screw
Main valves
14400 kPa (2100 psi)
Line relief valve
11000 kPa (1600 psi)
Note: Pressure values in Table 27 are approximate

values. Use a pressure gauge for adjustment.
Note: Normal operations of the engine and pumps
are necessary for the pressure adjustments. If the
results of the pressure adjustment are not correct,
needs to be checked. Slow output flow from the
pump is an indication of air in the hydraulic system.
Make sure that no air is present in the hydraulic
system. Refer to Testing And Adjusting, "Air (Main
Hydraulic Pump) - Purge".
pressure rise.
Illustration 38
Pump compartment
(1) Pressure tap for delivery pressure from the right pump (drive
pump)
(2) Pressure tap for delivery pressure from the left pump (idler
pump)

2. Stop the engine.
4. Connect a 60000 kPa (8700 psi) pressure
gauge to pressure tap (1). Connect a 60000 kPa
(8700 psi) pressure gauge to pressure tap (2).
pressure tap (3). This is used to monitor power
shift pressure.
Performance Test" for engine rpm settings.
55 5C (131 9F).
32
Hydraulic System
9. Slowly move the joystick for the bucket to the
BUCKET OPEN position (bucket cylinder rod at
the fully retracted position).
10. Check the main relief valve pressure setting at
pressure tap (1).
NEUTRAL position.
12. The main relief valve pressure setting should be
34300 490 kPa (4950 72 psi). If the main
relief valve is not within the specification, adjust
the main relief valve pressure setting to the
correct pressure specification before performing
Step 13. Refer to Testing and Adjusting, "Main
Relief Valve - Test and Adjust".
17. Check the pressure in the boom cylinder head

position.
19. The pressure setting of the boom line relief
valve is read at pressure tap (1). The pressure
setting of the boom line relief valve should be
36800 1470 kPa (5350 2 1 5 psi). If the
boom lowering control valves are set at a lower
pressure, the boom lowering control valves will
relieve pressure first. A lower pressure will be
read. Continue to step 20.
20. A temporary setting of the head end of the
boom line relief valve is required before the
boom lowering control valve can be adjusted.
To make the temporary setting, loosen locknut
(14) on the line relief valve for the head end of
the boom cylinder. Turn adjustment screw (15)
for one half turn. Tighten the locknut. This should
ensure that the line relief valve is high enough.
21. The following test and adjustment procedures
properly set the boom lowering control valves
on each of the boom cylinders. The temporary
settings of the main relief valve and the line
relief valve must be performed before the boom
lowering control valves are set.
Illustration 39
900666196
Top of main control valve
22. During the following procedure, carefully note

the number of turns for adjustment screw (19).
Also, take note of the direction of the turns.

(5) Locknut
13. A temporary setting of the main relief valve

is required before any line relief valve can
be adjusted. To make the temporary setting,
loosen locknut (5) and turn adjustment screw (4)
clockwise for one half turn. Tighten locknut (5).
Use the torque specification in Table 25.
14. Refer to Systems Operation/Testing and
Adjusting, RENR 3814, "320C Excavator Engine
and Pump Control", "Using Service Mode". Start
service mode. Adjust the power shift pressure.
Input a fixed power shift pressure of 2900 kPa
(420 psi).
15. The permanent pressure setting for the head
end of the boom cylinder is 36800 1470 kPa
(5350 2 1 5 psi).
the boom cylinder head end, move the joystick
for the boom until the boom is at the full BOOM
RAISE position (full extension of boom cylinders).
Hold the joystick for the boom in this position.
Illustration 40
(19)
(20)
(21)
(22)
(23)
Adjustment screw
Locknut
Relief valve
Boom lowering control valve
Manual valve for boom lowering
23. Loosen locknut (20) on the boom lowering

control valve for the left cylinder. Turn adjustment
screw (19) clockwise until the adjustment
screw contacts the bottom. Do not overtighten
adjustment screw (19). Be sure to remember
the number of turns. Tighten locknut (20).
24. Move the joystick for the boom to the full BOOM
RAISE position. Hold the joystick for the boom
in this position and check the pressure gauge
reading at pressure tap (1).
position.
26. The pressure gauge reading should be
36800 1500 kPa (5350 215 psi). If the
not within the specification, adjust the relief valve
on the right cylinder. In order to adjust the relief
valve, loosen locknut (20) on the right boom
lowering control valve. Turn adjustment screw
(19). Tighten the locknut.
27. Recall the number of clockwise turns on the left
boom lowering control valve. Loosen locknut (20)
on the left boom lowering control valve. Reverse
adjustment screw (19). Make the recalled
number of turns. Make one additional quarter
turn in order to decrease the pressure setting
below 36800 1500 kPa (5350 215 psi).
Tighten the locknut.
28. Fully extend the boom cylinders. Hold the
implement control lever in the Boom Raise
position. Read the pressure at pressure tap (1).
position.
30. The pressure gauge reading should be
36800 1500 kPa (5350 2 1 5 psi). If the
pressure gauge reading at pressure tap (1) is not
within the specification, adjust the relief valve. In
order to adjust the relief valve, loosen locknut
(20) on the left boom lowering control valve. Turn
adjustment screw (19). Tighten the locknut.
31. Reset the line relief valve for the head end
of the boom cylinder. Refer to Testing and
Adjusting, RENR3817, "Relief Valve (Line) - Test
and Adjust".
32. Refer to Systems Operation/Testing and
Adjusting, RENR3814, "320C Excavator Engine
and Pump Control", "Using Service Mode". Exit
service mode.
33. Reset the main relief valve pressure after
resetting the line relief valve. Refer to Testing
and Adjusting, RENR3817, "Relief Valve (Main) Test and Adjust".
34
Hydraulic System
Pump Flow Measurement

and Adjustment
Main Pump (Flow) - Test
(Constant Horsepower Flow
Control)
SMCS Code: 5070-081-FW
This test measures individual pump flow at the
pump. Each pump is tested individually for output
flow at specified pressures. The pump that is not
being tested is not under load and the pump
remains at low pressure standby.
Illustration 41
The electronic control module is located in the compartment
behind the cab.
(1) Alarm lamp
(2) Electronic control module
Illustration 42
(3) Monitor
(4) Message display
Note: Before starting main pump flow tests, check

message display (4) on monitor (3) and alarm lamp
(1) on electronic control module (2) for normal
operation. If no faults are present, perform the
operational checks. Refer to Testing And Adjusting,
"Operational Checks".
Note: If the operational checks (cycle time) indicate
that slow speed of an implement is common to the
circuits of one pump, the problem is most likely in
the hydraulic system. Then perform the pump flow
tests. Refer to Testing And Adjusting, "Main Pump
(Flow) - Test".
Note: The engine, the fuel, or the working altitude
may be the problem if the operational checks
indicate that slow speed of an implement is common
to both pump circuits.
35
Hydraulic System
Illustration 43
Flow meter tool layout
(1) Swing motor
(2) Connector at swing motor
(3) 6V - 9840 Swivel tee
(4) Makeup Line (swing motor)
(6) Negative flow control line (right pump)
(10) 4C-9910 Portable hydraulic tester (flow
meter)
(11) Delivery line (left pump)
(12) Delivery line (right pump)
(13) Negative flow control line (left pump)
(17)
(23)
(24)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
9U-7335 Blocking cover

Right pump
Left pump
1U-8303 Fitting
5K-9090 O-Ring seal
5P-0201 Hose
5P-1010 Sleeve
4C-8767 Coupling
7M-8485 O-Ring seal
4C-6481 Coupler assembly
(36)
(37)
(38)
(39)
(40)
(42)
(46)
(47)
(48)
(49)
4C-6482 Nipple assembly

4I-6141 Coupling
8C - 9026 Adapter
6K-6307 O-Ring seal
6V-9854 Swivel elbow
1P-3703 Rectangular seal
8T-4184 Bolt
8T-4223 Hard washer
6V-0400 Half flange
1U-8292 adapter
36
Hydraulic System
Right Pump
NOTICE
products.
mandates.
Note: Perform the test for the right pump and the
test for the left pump one at a time.
Illustration 44
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(9) 8T-0861 Pressure gauge
(10) 4C-9910 Portable hydraulic tester (flow meter)
(11) Delivery line for left pump
(12) Delivery line from right pump
(17) 9U-7335 Blocking cover
(21) Engine
(22) Multitach
(23) Right pump
(24) Left pump
(40) Elbow
Illustration 45
Pump compartment
(12) Delivery line for right pump
(23) Right pump
(24) Left pump

2. Stop the engine.
4. Install the following tools in accordance with the
flow meter tool layout and the circuit diagram.
Refer to Illustration 43 and Illustration 44.
a. Disconnect delivery line (12) from right pump
(23).
37
Hydraulic System
b. Install seal (42), half flanges (48) and blocking
cover (17) to the end of delivery line (12) by
using bolts (46) and washers (47).
c. Assemble and install seal (42), adapter (49),
seals (34), fitting (29) and nipple assembly
(36) on right pump (23) by using half flanges
(48), bolts (46) and washers (47).
Left Pump
NOTICE
products.
mandates.
ustration 46
Swing motor (top view)
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow
d. Disconnect makeup line (4) from connector

(2) at swing motor (1).
e. Assemble and install seals (30), tee (3), swivel
elbow (40) and coupling (37) to connector
f. Install seal (30) and makeup line (4) to tee (3).
g. Connect portable hydraulic tester (10) and
the test hoses between nipple assembly (36)
at right pump (23) and coupling (37) at the
swing motor.
h. Connect 60000 kPa (8700 psi) pressure
gauge (9) to pressure tap (16) for right pump
delivery pressure.
i. Install multitach group (22) on engine (21).
This is used to monitor engine speed.
Illustration 47
Pump compartment
(11) Delivery line for left pump
(23) Right pump
(24) Left pump

2. Stop the engine.
a. Disconnect delivery line (11) from left pump
(24).
38
Hydraulic System
(36) on left pump (24) by using half flanges
WARNING
To prevent personal injury and/or equipment damage from failed lines or components while the hydraulic test equipment is returned to the open flow
position, slowly open the hydraulic test equipment
valve while monitoring the pump flow.
If pump flow does not increase as the valve is
opened, shut the engine off and determine what
is preventing the pump from upstroking.
OFF, Refer to Testing And Adjusting, "Engine
illustration 48

55 5C (131 9F).

(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow

swing motor.
gauge (9) to pressure tap (8) for left pump
delivery pressure.
Test
Note: Perform the test for the front pump and the
test for the rear pump one at a time.
WARNING
To prevent personal injury or equipment damage
from failure of the hydraulic test equipment or associated circuit components because of blocked
pump flow, make sure that the test equipment
valves are fully open before starting the engine.
Illustration 49
Monitor
(A) Message display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Set key
(I) OK key
(J) Menu key
39
Hydraulic System
pressure of 2400 50 kPa (350 7 psi).

on Service Mode.

5. In order to perform flow measurements for either

one of the pumps, the other pump must not be
under load.

Illustration 50
Portable hydraulic tester (flow meter)

(10) Portable hydraulic tester (flow meter)

(22) Multitach
(26) Valve
6. Turn valve (26) on portable hydraulic tester (10)

clockwise. Record pump flow at each of the
following pressures in Table 28. Use pressure
gauge (9) at pressure tap (16) to monitor right
pump delivery pressure or use pressure tap (8)
to monitor left pump delivery pressure.

attained on the pressure gauge that is connected
to the pressure tap for power shift pressure. The
actual power shift pressure must be 2400 50 kPa
(350 7 psi) on the pressure gauge.
during the pump flow test, do not turn the engine
start switch to the OFF position.
Illustration 51
P-Q characteristic curve
40
Hydraulic System
Table 28
Pump Flow Test
Measuring Points
Flow measured liter/min

(US gpm)
9800 kPa
(1425 psi)
15700 kPa
(2300 psi)
19600 kPa
(2850 psi)
25500 kPa
(3700 psi)
29400 kPa
(4250 psi)
110 10 ' 86 10
(29.0 2.6) (22.7 2.6)
75 10
(19.8 2 . 6 )
Right Pump
Left Pump
Oil temperature C (F)
Engine speed (rpm)

Flow corrected liter/min
(US gpm)
Right Pump
Specification for flow rate

liter/min (US gpm)
New
172 10
(45.4 2.6)
135 10
(35.6 2.6)
Service limit
155 (41)
103(27)
Left Pump
Note: Specifications for output flow rates are based

on an engine speed of 1800 rpm. To attain more
accurate test results, measured flow should be
corrected with the following calculation.
Table 29
Corrected flow
Note: Specifications for output flow rates are

based on a power shift pressure at the pump of
2400 50 kPa (350 7 psi). The output flow rate
changes approximately 6 L/min (1.6 US gpm) for
each 100 kPa (14 psi) of power shift pressure in
the lower range of the constant horsepower control.
The output flow rate changes approximately 3 L/min
(0.8 US gpm) for each 100 kPa (14 psi) of power
shift pressure in the higher range of the constant
horsepower control.
83 (22)
56 (15)
48 (13)
Pump Control (Output Flow) Adjust

Adjust the pump output flow if the flow test results
differ greatly from the specifications.
Adjustment of Pump Output Flow

(Constant Horsepower Control)
Note: If the output flow rate of the pump is not

within the specification, disconnect the negative
flow control line from the pump that is being tested
and perform the test again.
Note: Flow measurements must be done only during
pressure rise.
Illustration 52
Main pump compartment
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Adjustment
Locknut
Adjustment
Locknut
Adjustment
Locknut
Adjustment
Locknut
screw
screw
screw
screw
41
Hydraulic System
Adjust the flow of the right pump for the first stage
of the constant horsepower control. The left pump
must be at no-load condition.
Adjustment of the Maximum Output

Flow of the Pump
1. Loosen locknut (23).

2. Turn adjustment screw (22) in order to adjust
the output flow of the pump. Turning adjustment
screw (22) clockwise will increase the output
flow of the pump. Turning adjustment screw (22)
counterclockwise will decrease the output flow of
the pump. A 1/4 turn of adjustment screw (22)
will change the output flow of the pump at the
following pressure.
Output flow of the pump will change
approximately 19 L/min (5.0 US gpm) if the
output flow is adjusted in the pressure range of
11800 kPa (1700 psi) to 19600 kPa (2850 psi).
The pump is operating in the first stage of the
constant horsepower control.
3. Tighten locknut (23) to a torque of 98 9.8 N-m
(70 7 lb ft).
Adjust the flow of the right pump for the second
stage of the constant horsepower control. The left
pump must be at no-load condition.
2. Turn adjustment screw (20) in order to adjust
the output flow of the pump. Turning adjustment
screw (20) clockwise will increase the output
counterclockwise will decrease the output flow of
the pump. A 1/4 turn of adjustment screw (20)
will change the output flow of the pump at the
following pressure.
Output flow of the pump will change
approximately 13 L/min (3.4 US gpm) if the
output flow is adjusted in the pressure range of
27500 kPa (4000 psi) to 34300 kPa (4950 psi).
The pump is operating in the second stage of
the constant horsepower control.
(21 5 lb ft).
Adjust the left pump in the same manner as the
right pump. Use locknut (27) and adjustment
screw (26) in order to adjust the first stage of the
constant horsepower control. Use locknut (25) and
adjustment screw (24) in order to adjust the second
stage of the constant horsepower control.
Main pump compartment

(28)
(29)
(30)
(31)
Adjustment screw
Locknut
Locknut
Adjustment screw
Adjust the maximum output flow of the right pump.

2. In order to adjust maximum output flow, turn
adjustment screw (31). Turning adjustment screw
(31) clockwise will decrease the maximum output
counterclockwise will increase the maximum
output flow of the pump. A 1/4 turn of adjustment
screw (31) will change the maximum output flow
approximately 5 L/min (1.3 US gpm).
(130 11 lb ft).
Adjust the maximum output flow of the left pump in
the same manner as the right pump. Use locknut
(29) and adjustment screw (28) in order to adjust
the maximum output flow of the left pump.
Pump Control (Negative Flow)

- Test
This test measures individual pump flow at the
pump while a fixed negative flow control pressure
is sent to the main pump regulator. Each pump
is tested individually for an output flow rate at a
specified delivery pressure and a specified negative
flow control pressure.
42
Hydraulic System
Illustration 54
(1) Swing motor
(2) Connector at swing motor
(3) 6V-9840 Swivel tee
(4) Makeup Line (swing motor)
(10) 4C-9910 Portable hydraulic tester (flow
meter)
(17)
(23)
(24)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
9U-7335 Blocking cover

Right pump
Left pump
1U-8303 Fitting
5K-9090O-Ring seal
5P-0201 Hose
5P-1010 Sleeve
40-8767 Coupling
7M-8485 0-Ringseal
4C-6481 Coupler assembly
(36) 4C-6482 Nipple assembly

(37)4I-6141 Coupling
(38) 8C-9026 Adapter
(39) 6K-6307O-Ring seal
(40) 6V-9854 Swivel elbow
(42) 1P-3703 Rectangular seal
(46) 8T-4184Bolt
(47) 8T-4223 Hard washer
(48) 6V-0400 Half flange
(49) 1U-8292 Adapter
43
Hydraulic System
Right Pump
NOTICE
products.
mandates.
Illustration 55
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valves
(7) Plug
(9) Pressure gauge
(15) Tees
(16)
(17)
(18)
(20)
(21)
(22)
(23)
(24)
(40)
Pressure tap (right pump delivery pressure)

Blocking cover
Test line
Pressure gauge
Engine
Multitach group
Right pump
Left pump
Elbow
Illustration 56
Pump compartment
(23) Right pump
(24) Left pump

2. Stop the engine.
circuit diagram. Refer to Illustration 55.
a. Disconnect delivery line (12) from right pump
(23).
44
Hydraulic System
(36) on right pump (23) by using half flanges
Illustration 57
g00669270

(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow

swing motor.
gauge (9) to pressure tap (16) for right pump
delivery pressure.
Illustration 58
Tool setup
(7) 6V-9508 Face seal plug
(15) 8T-8902 Tee
(18) 177-7860 Hose assembly
(19) Left pump regulator
(23) Right pump
(24) Left pump
(25) 6V-8397 0-Ring seal
(27) 6V-9829 Cap
(28) 3J -1907 O-Ring seal
(41) 6V-3965 Fitting
(43) 6V-4143 Coupler
(44) Test hose
(45) 6V-3989 Fitting
j. Disconnect negative flow control line (6) from

right pump (23). Install seal (25) and plug (7)
to the end of negative flow control line (6).
k. Connect two tees (15) to the elbow at the
negative flow signal pressure port of right
pump (23). Install cap (27) to tee (15).
I. Connect one end of test hose (18) to tee (15).
m. Connect the other end of test hose (18) to
pressure tap (14) for the power shift pressure.
n. Connect one end of test hose (44) to tee (15).
45
Hydraulic System
o. Connect 6000 kPa (870 psi) pressure gauge
(20) to the other end of test hose (44).
Left Pump
NOTICE

(36) to left pump (24) by using half flanges

products.
mandates.
Illustration 60
900669270

(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow

f. Install seal (30) and makeup line (4)to tee (3).
Illustration 59
Pump compartment
(23) Right pump
(24) Left pump

2. Stop the engine.
circuit diagram. Refer to Illustration 55.
a. Disconnect delivery line (11) from left pump
(24).

at left pump (24) and coupling (37) at the
swing motor.
gauge (9) to pressure tap (8) for left pump
delivery pressure.
46
Hydraulic System
o. Connect 6000 kPa (870 psi) pressure gauge
(20) to the other end of test hose (44).
Test
WARNING
WARNING
To prevent personal injury and/or equipment damage from failed lines or components while the hydraulic test equipment is returned to the open flow
position, slowly open the hydraulic test equipment
valve while monitoring the pump flow.
Illustration 61
If pump flow does not increase as the valve is

opened, shut the engine off and determine what
is preventing the pump from upstroking.
Tool setup
(7) 6V-9508 Face Seal Plug
(15) 8T-8902 Tee

(18)
(19)
(20)
(23)
(24)
(25)
(27)
(28)
(41)
(43)
(44)
(45)
177-7860 Hose Assembly

Left pump regulator
8T-0855 Pressure Gauge
Right pump
Left pump
6V-8397 O-Ring Seal
6V-9829 Cap
3J -1907 O-Ring Seal
6V-3965 Fitting
6V-4143 Coupler
Test hose
6V-3989 Fitting
j. Disconnect negative flow control line (13) from

left pump (24). Install seal (25) and plug (7)
to the end of negative flow control line (13).
k. Connect two tees (15) to the elbow at the
negative flow signal pressure port of left pump
(24). Install cap (27) to tee (15).
I. Connect one end of test hose (18) to tee (15).
m. Connect the other end of test hose (18) to
pressure tap (14) for the power shift pressure.
n. Connect one end of test hose (44) to tee (15).

55 5C (131 9F).
47
Hydraulic System
e. Press right key (F) repeatedly until 'DEVICE
g. Press right key (F) until the "PS PRV - FIXED'
Illustration 62
Monitor
(A) Message display
(B) Keypad
(C) Up key
(D) Left key
(E) Down key
(F) Right key
(G) Cancel key
(H) Set key
(I) OK key
(J) Menu key


during the pump flow test, do not turn the engine
start switch to the OFF position.
Note: Refer to Service Manual, "Engine and Pump
on Service Mode.

b. Press down key (E) in order to highlight the
second menu item "SERVICE OPTIONS" on
the message display. Press OK key (I).
Illustration 63
(22) Multitach
(26) Valve
48
Hydraulic System
5. Turn valve (26) on portable hydraulic tester (10)
clockwise until the pump delivery pressure is
6850 kPa (1000 psi).
Flow measurements must be done in pressure rise.
6. Record the negative flow rate in Table 30.
Pump Control (Negative Flow)

- Adjust
Illustration 64
Pressure/Flow characteristic curve
Table 30
Negative Flow Control at 2350 kPa (340 psi)

Right pump
Oil Temperature C (F)
Engine speed (rpm)
Left pump
Right pump
Left pump
Flow measured liter/min

(US gpm)
Right pump
Row corrected liter/min

(US gpm)
Right pump
Specification for negative

flow rate liter/min (US gpm)
Left pump
Left pump
Illustration 65
New
108 10
(29.0
2.6)
Service limit
88 (23)
Note: Specifications for flow rates are based on an

engine speed of 1800 rpm. To get more accurate
test results, measured flow should be corrected with
the following calculation.
Table 31
Corrected flow
g00668985
Pump regulator (right pump)

(1)
(2)
(3)
(4)
(5)
(6)
Bolt
Cover
Seal
Spring seat
Spring
Shim
Perform the following steps in order to adjust the

right pump.
1. Remove two bolts (1).
2. Remove cover (2) and seal (3).
3. Remove spring seat (4) and spring (5).
49
Hydraulic System
4. Add shims (6) in order to increase the negative
flow. Remove shims (6) in order to decrease the
negative flow. Refer to Table 32 for available
shims and shim thickness.
Note: A change of 0.1 mm (0.0039 inch) in shim
thickness will change the negative flow rate 3 L/min
(0.8 US gpm) at a negative flow control pressure of
2350 kPa (340 psi).
Table 32
Available Shims
Part Number
Shim Thickness
099-3669 Shim
1.00 mm (0.0394 inch)
099-6109 Shim
1.05 mm (0.0413 inch)
099-6110 Shim
1.10 mm (0.0433 inch)
099-6111 Shim
1.15 mm (0.0453 inch)
099-6112 Shim
1.20 mm (0.0472 inch)
099-6113 Shim
1.25 mm (0.0492 inch)
099-6115 Shim
1.30 mm (0.0512 inch)
099-6117 Shim
1.35 mm (0.0531 inch)
099-6118 Shim
1.40 mm (0.0551 inch)
099-6119 Shim
1.45 mm (0.0571 inch)
099-6120 Shim
1.50 mm (0.0591 inch)
099-6121 Shim
1.55 mm (0.0610 inch)
099-6122 Shim
1.60 mm (0.0630 inch)
099-6123 Shim
1.65 mm (0.0650 inch)
099-6124 Shim
1.70 mm (0.0669 inch)
099-6125 Shim
1.75 mm (0.0689 inch)
099-6126 Shim
1.80 mm (0.0709 inch)
099-6127 Shim
1.85 mm (0.0728 inch)
099-6128 Shim
1.90 mm (0.0748 inch)
099-3670 Shim
1.95 mm (0.0768 inch)
5. Install shims (6) in the pump regulator.

6. Install spring (5). Install spring seat (4).
7. Install cover (2) and seal (3).
Note: Inspect seal (3). If the seal is damaged,
replace the damaged seal with a new seal.
8. Install bolts (1). Tighten bolts (1) to a torque of
55 10 N.m (40 7 lb ft).
Adjust the left pump in the same manner as the
right pump.
Gear Pump (Pilot) - Test

SMCS Code: 5085-081 -GT
50
Hydraulic System
Illustration 66
(1)
(2)
(3)
(4)
(6)
(7)
Swing motor
Connector at swing motor
6V-9840 Swivel Tee
Makeup line (swing motor)
6V-9509 Face Seal Plug
4C-9910 Portable hydraulic tester (flow
meter)
(8) Pilot line (delivery line from the pilot
pump)
(9) Connector at pilot pump

(10) Pilot filter
(14) Pilot pump
(30) 5K-9090 O-Ring Seal
(31) 5P-0201 Hose
(32) 5P-1010 Sleeve
(33) 4C-8767 Coupling
(34) 7M-8485 O-Ring Seal
(35) 4C-6481 Coupler Assembly
WARNING
(36) 4C-6482
(37)41-6141
(38) 8C-9026
(39) 6K-6307
(40) 6V-9854
(47) 41-6140
(48) 8C-8762
(49) 6V-8398
Nipple Assembly
Coupling
Adapter
O-Ring Seal
Swivel Elbow
Coupling
Elbow
O-Ring Seal
51
Hydraulic System
NOTICE
products.
mandates.
2. Stop the engine.
Illustration 67
Circuit diagram
(1) Swing motor
(2) Connector
(3) Tee
(4) Makeup line
(5) Main control valve
(6) Plug
(7) Portable hydraulic tester
(8) Pilot line
(9) Connector at pilot pump
(10) Pilot filter
(12) Engine
(13) Multitach group
(14) Pilot pump
(40) Elbow

a. Install multitach group (13) on engine (12).
b. Remove pilot line (8) from the connector at
pilot pump (14).
c. Install seal (49) and plug (6) to the end of
pilot line (8).
d. Install seal (49) and elbow (48) to connector
(9) at pilot pump (14).
e. Install seal (34), coupling (47), seal (34) and
nipple assembly (36) to elbow (48).
52
Hydraulic System
Illustration 68
Illustration 69
Swing motor
(1) Swing motor

(2) Connector
(3) Tee
(4) Makeup line
(40) Elbow

(13) Multitach group
(16) Valve (flow meter)
f. Disconnect makeup line (4) from connector

g. Assemble and install seals (30), tee (3), swivel
8. Turn valve (16) on portable hydraulic tester

(7) clockwise until pressure gauge (11) on the
portable hydraulic tester shows a reading of
4100 200 kPa (595 29 psi).
9. Record the pilot pump flow at 4100 200 kPa
(595 29 psi) in Table 33.
Table 33
h. Connect portable hydraulic tester (7) and test

hoses between nipple assembly (36) at the
pilot pump and coupling (37) at the swing
motor.
Pump Flow Test

Oil temperature C (F)
Engine speed (rpm)
Flow measured liter/min (US gpm)

Flow corrected liter/min (US gpm)
Specification for pump flow

liter/min (US gpm)

55 5C (131 9F).
New
36 + 2
(9.5
0.5)
Service
limit
30 (7.9)
Note: Specifications for pump flow are based on an

engine speed of 1800 rpm. To get more accurate
test results, measured flow should be corrected by
the following calculation.
Table 34
Flow measurements must be done in pressure rise.
53
Hydraulic System
Hydraulic Motor and Pump

Performance Tests
3. Disconnect the case drain hose (1) from tee (2).

Place the open end of the case drain hose (1)
into the container for measuring.
4. Install 6V-8398 O-Ring seal and 6V-9830 Cap
on tee (2) of the swivel.
Swing Motor - Test

(Measurement of Case Drain
Oil)
Table 35
Required Tools
Part
Number
6V-9830
Description
Qty
Cap
Container for Measuring
Illustration 71
Pilot manifold
NOTICE
(3) Connector
(4) Solenoid valve for swing parking brake
5. Disconnect connector (3) from the solenoid valve

for swing parking brake (4).

products.
7. Place the engine speed dial at position "10" and

AEC switch OFF. Maintain the maximum no-load
speed at 1860 50 rpm.

mandates.
Reference: Refer to Testing and Adjusting,

settings.
1. Stop the engine.

55 5C (131 9F).

9. Slowly move the swing joystick and make sure

that the swing parking brake is activated.
10. Move the swing joystick fully for one minute.
Measure the case drain oil.
11. Stop the engine.
12. Connect connector (3) to the solenoid valve for
swing parking brake (4).
13. Repeat this test procedure three times in order
to obtain three measurements. For each test
procedure, swing the upper structure to a
different position.
Illustration 70
Swing motor compartment
(1) Case drain hose
(2) Tee
The following values specify the maximum

acceptable flow of case drain oil when the
swing relief pressure is set at 26000 980 kPa
(3750 140 psi).
54
Hydraulic System
New swing motor
Rebuilt swing motor
30 L/min (7.9 US gpm)

Travel Motor - Test

(Measurement of Case Drain
Oil)
SMCS Code: 4351-081
Table 36
Required Tools
Illustration 72
Part
Number
Description
FT-2547
Track block assembly
6V-9509
Face Seal Plug
6V-8398
O-Ring Seal
Remote drain hose with an

inside diameter of 20 mm
(.78 inch)
Qty
Sprocket (left track)

(1) Sprocket
(2) FT-2547 Track block assembly
3. Place track block assembly (2) in sprocket (1)

in order to block forward left travel. Refer to
Illustration 72.
NOTICE
Tools and Shop Products Guide" fortools and supplies
products.
mandates.
1. Stop the engine.
Illustration 73
Travel motor

(3)
(4)
(5)
(6)
(7)
(8)
6V-9509 Face seal plug

6V-8398 O-Ring seal
Case drain hose
Connector
Remote drain hose
4. Disconnect case drain hose (5) from connector

(6). Install plug (3) and seal (4) in the open end
of case drain hose (5).
5. Connect one end of remote drain hose (7) to
connector (6). Place the other end of remote
drain hose into the container (8) in order to
measure the case drain oil.
55
Hydraulic System
7. Place the engine speed dial at position "10" and
AEC switch OFF. Maintain the maximum no-load
speed at 1860 50 rpm.
Reference: Refer to Testing and Adjusting,
settings.
55 5C (131 9F).
9. Move the left travel lever forward fully for one
minute.
10. Measure the amount of case drain oil.
11. Remove track block assembly (2) from sprocket
(1).
12. Move the left travel lever in order to reposition
the travel motor.
13. Place track block assembly (2) in sprocket (1) in
order to block forward left travel.
14. Repeat Steps 9 through 13 in order to obtain
three measurements of case drain oil.
The following values specify the maximum
acceptable flow of case drain oil when the main
relief valve pressure is set at 34300 490 kPa
(4950 72 psi) and the travel crossover relief valves
are set at 36800 1470 kPa (5350 215 psi).
New travel motor
Rebuilt travel motor

56
Hydraulic System
Specifications
SMCS Code: 5050
Note: A New specification is the performance
that can be expected for a new machine. A
Rebuild specification is the performance that can
be expected after rebuilding the components
of a system. Performance beyond Service Limit
specifications is an indication of these problems:
improper adjustment, wear, damage of relief valves,
and damage of pumps.
Illustration 74
Relief valve locations
(B) Boom cylinder line (head end)
(C) Boom cylinder line (rod end)
(D) Stick cylinder line (head end)
(E) Stick cylinder line (rod end)
(F) Bucket cylinder line (head end)
(G) Bucket cylinder line (rod end)
(H) Swing (right)
(I) Swing (left)
(J) Left travel crossover relief valve for

forward travel (upper valve)
(K) Left travel crossover relief valve for
reverse travel (lower valve)
(L) Right travel crossover relief valve for
forward travel (upper valve)
(M) Right travel crossover relief valve for
reverse travel (lower valve)
(N) Pilot relief valve
(O) Main control valve

(P) Pilot filter
(Q) Travel motor (right)
(R) Travel motor (left)
(S) Swing motor
57
Hydraulic System
Table 37
Specifications
Relief Valve
New
Rebuilt
Service Limit
34300 + 490 kPa (4950 72 psi)
32340 to 34790
kPa (4700 to
5050 psi)
Torque for
Locknut
CHS Inspection
Step NumberO)
50 10 N-m
(37 7 lb ft)
115
(B) Boom cylinder line

(head end)
138
(C) Boom cylinder line (rod

end)
(D) Stick cylinder line
(head end)
36800 1470 kPa (5350 215 psi)
(E) Stick cylinder line (rod

end)
33850 to 38270
kPa (4920 to
5565 psi)
136
20 2 N-m
(14 1 lb ft)
134
(F) Bucket cylinder line

(head end)
140
(G) Bucket cylinder line

(rod end)
142
(H) Swing relief pressure

(right)
26000 980 kPa (3750 140 psi)
(1) Swing relief pressure

(left)
24040 to 26980
kPa (3465 to
3890 psi)
147
117.6 10 N-m
(85 7 lb ft)
(J) Left travel crossover

relief valve (forward)
(K) Left travel crossover
relief valve (reverse)
(L) Right travel crossover
relief valve (forward)
151
36800 1470 kPa (5350 215 psi)
33850 to 38270
kPa (4920 to
5565 psi)
154
130 13 N-m
(95 10 lb ft)
(M) Right travel crossover

relief valve (reverse)
(N) Pilot relief valve
145
157
160
4100 200 kPa (595 29 psi)
49 4.9 N-m
(36 4 lb ft)
50
(1) Custom Hydraulic Service (CHS) is a preventive maintenance program for the machine hydraulic system. CHS is also a valuable part
of any Customer Support Agreement. Refer to Custom Hydraulic Service, SEBF8472.
58
Hydraulic System
Table 38
Cycle Times (seconds)
Factory
CHS Inspection Step Number*1)
Boom EXTEND
2.8 0.5
192
Boom RETRACT
1.9 0.5
Stick EXTEND
3.2 0.5
195
Stick RETRACT
2.4 0.5
197
Bucket EXTEND
3.3 0.5
199
Bucket RETRACT
1.8 0.5
201
5.2(2)
208
1100 mm (43.3 inch)<2>
209
Function
Swing LEFT
Swing RIGHT
Overswing LEFT
Overswing RIGHT
Forward travel HIGH (Left)
14.0(2)
Reverse travel HIGH (Left)
217
Forward travel LOW (Left)
22.0(2)
Reverse travel LOW (Left)
Forward travel HIGH (Right)
14.0(2)
Reverse travel HIGH (Right)
218
Forward travel LOW (Right)
22.0(2)
Reverse travel LOW (Right)
(2) Maximum
Table 39
Cylinder Drift (Empty Bucket)
Function
Factory
Boom cylinder
6.0 mm (0.24 inch)
Stick cylinder
10.0 mm (0.39 inch)
Bucket cylinder
10.0 mm (0.39 inch)
CHS Inspection Step Number*1)

228
237
Table 40
Required Tools
Part
Number
Description
Qty
9U-7400
8T-0470
Thermometer group
59
Hydraulic System
Table 41
Relief Valves
Pressure change With

One Turn Of Adjustment
Screw
Main valves
14400 kPa (2100 psi)
Line relief valve
11000kPa(1600psi)
Swing relief valve
6800 kPa (985 psi)
Travel crossover relief valve
3050 kPa (440 psi)
Pilot relief valve
620 kPa (90 psi)
Note: Pressure values in Table 41 are approximate

values. Use a pressure gauge for adjustment.
Note: Normal operations of the engine and pumps
are necessary for the pressure adjustments. If the
results of the pressure adjustment are not correct,
needs to be checked. Slow output flow from the
pump is an indication of air in the hydraulic system.
Make sure that no air is present in the hydraulic
system. Refer to Testing And Adjusting, "Main
Hydraulic Pump Air Pressure - Purge".
Index
c
Control Valve (Boom Lowering) - Test and Adjust..
Cylinder Drift - Check (Empty Bucket)
Cylinder Drift - Check (Loaded Bucket)
30
16
15
17
E
Engine Performance - Test (Engine Speed)
Pump Control (Negative Flow) - Test

41
Left Pump
45
Right Pump
43
Test
46
Pump Control (Output Flow) - Adjust
40
Adjustment of Pump Output Flow (Constant
Horsepower Control)
40
Adjustment of the Maximum Output Flow of the
Pump
41
Pump Flow Measurement and Adjustment
34
3
R
G
Gear Pump (Pilot)-Test
General Testing and Adjusting Information
49
4
H
Hydraulic Motor and Pump Performance Tests
53
Hydraulic Pressure Adjustments
19
Hydraulic System Pressure - Release
4
Release Of Hydraulic Pressure From A Single
Hydraulic Circuit
5
Release Of Hydraulic Pressure From Multiple
Hydraulic Circuits
6
Relief Valve (Crossover) - Test and Adjust
Relief Valve (Line) - Test and Adjust
Adjustment (Boom Cylinders)
Adjustment (Bucket Cylinder)
Adjustment (Stick Cylinder)
Test
Relief Valve (Main) - Test and Adjust
Temporary Setting of the Main Relief Valve
Relief Valve (Pilot) - Test and Adjust
Relief Valve (Swing) - Test and Adjust
Required Tools
56
21
24
27
27
26
24
20
21
20
28
19
S
I
Important Safety Information
M
Machine Drift on a Slope - Check
12
Main Hydraulic Pump Air Pressure - Purge
7
Main Pump (Flow) - Test (Constant Horsepower Flow
Control)
34
Left Pump
,
37
Right Pump
36
Test
38
o
Operational Checks
Solenoid Valve (Swing Parking Brake) - Test

Specifications
Swing Motor - Test (Measurement of Case Drain
Oil)
Swing Speed and Overswing on Level Ground Check.,
Swing Speed and Swing Drift on a Slope - Check..
29
56
53
13
14
T
Table of Contents
,
3
4
4
Travel Motor - Test (Measurement of Case Drain
Oil)
54
11
Travel on Level Ground - Test (Optional Test)
10
9
V
P
Visual Inspection
Performance Tests
Pump Control (Negative Flow) - Adjust...
2001 Caterpillar
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CATERPILLAR

320C Excavator Hydraulic System

Important Safety Information

Pump Flow Measurement and Adjustment

Testing and Adjusting

Testing and Adjusting

A visual inspection of the system is the first step in

SMCS Code: 5050

2. Remove the hydraulic filter elements. Inspect the

3. Inspect all lines and connections for damage

Always move the machine to a location away from

4. Inspect control linkages for bent components,

The correct oil temperature, flow, and pressure are

Hydraulic System Pressure Release

Release Of Hydraulic Pressure

2. Fully retract the stick cylinder rod. Adjust the

Release Of Hydraulic Pressure

2. Fully retract the stick cylinder rod. Adjust the

Main Hydraulic Pump Air

1. While the engine is stopped, disconnect hose

12. Slowly loosen vent plug (5) until oil begins to

320C L Machine Configuration

0.9 m3 (1.17 yd3)

SMCS Code: 5050-535

Engine Performance - Test

Perform the following operational checks in order

Multitach Tool Group

1. Position the machine on level ground.

Testing and Adjusting, "Travel On Level Ground

2. Stop the engine.

Testing and Adjusting, "Machine Drift On A Slope

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

Testing and Adjusting, "Swing Speed And

4. Start the engine.

Testing and Adjusting, "Swing Speed And Swing

320C Machine Configuration

0.8 m3 (1.04 yd3)

5. Increase the hydraulic oil temperature to

No load high idle(2)

No load low idle

(1) AEC switch in the OFF position

Note: A New specification is the performance that

Travel on Level Ground - Test

1. Start the engine.

320C Time For Three Revolutions (time in seconds)

320C L Time For Three Revolutions (time in seconds)

(A) Preliminary run 5 m (16.4 ft)

(C) Bucket height 0.5 to 1 m (1.6 to 3.3 ft)

1. Travel distance must be at least 25 m (82 ft)

(B) Travel distance 20 m (65.6 ft)

2. Draw a 25 m (82 ft) straight line on travel test

Travel on Level Ground - Test

3. Start the engine.

10. The first 5 m (16.4 ft) are for a preliminary run.

Note: The following table represents the travel

1. Place the machine on a slope of 12 degrees. The

Machine Drift on a Slope Check

3. The bucket should be empty.

SMCS Code: 4095-535

4. To indicate the machine's relative position to the

Swing Speed and Overswing

1. Position the machine on level ground. Refer to

3. To indicate the relationship of the two positions,

8. Move the swing joystick in each direction and

320cl Hydraulic System-testing&Adjusting

320cl Hydraulic System-testing&Adjusting