You are on page 1of 92
SENR6167-01 Testing and Adjusting 5080 FRONT SHOVEL HYDRAULIC SYSTEM S/N 6XK1-UP http://engine.od.ua Use the bookmarks for

SENR6167-01

SENR6167-01 Testing and Adjusting 5080 FRONT SHOVEL HYDRAULIC SYSTEM S/N 6XK1-UP http://engine.od.ua Use the bookmarks for

Testing and Adjusting

5080 FRONT SHOVEL HYDRAULIC SYSTEM

S/N 6XK1-UP

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Testing and Adjusting 5080 FRONT SHOVEL HYDRAULIC SYSTEM Media

Testing and Adjusting

5080 FRONT SHOVEL HYDRAULIC SYSTEM

Media Number -SENR6167-01

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Testing and Adjusting 5080 FRONT SHOVEL HYDRAULIC SYSTEM Media
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Testing and Adjusting 5080 FRONT SHOVEL HYDRAULIC SYSTEM Media

Publication Date -03/10/1995

Date Updated -12/10/2001

NOTE: This manual is divided into the following two main sections:

  • 1. Checking Procedures

  • 2. Testing And Adjusting

NOTE: As a general rule, if there is doubt as to the cause of a problem, the electronic system should be checked first.

Reference: For information on Systems Operation of the above, make reference to: Engine And Pump Electronic Control System, Systems Operation, Testing And Adjusting, SENR6155 and/or Systems Operation, Hydraulic System, SENR6166 or SENR6294.

NOTE: The material in this module is intended to be used with the separate modules, "Electrical Schematic", Form No. SENR6128, SENR8939 or SENR6144. "Starting And Charging System, System Operation", and "Engine And Pump Electronic Control System, Systems Operation, Testing And Adjusting", Form No. SENR6155.

This manual contains information on the troubleshooting procedures of the hydraulic system in the 5080 Front Shovel. For troubleshooting the engine components, refer to the module Systems Operation, Testing And Adjusting for CAT 3406 ATAAC Diesel Engine, Form No. REGO1438.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Testing and Adjusting 5080 FRONT SHOVEL HYDRAULIC SYSTEM Media

In each checking procedure, it is assumed that the engine operation is normal unless otherwise specified.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Testing and Adjusting 5080 FRONT SHOVEL HYDRAULIC SYSTEM Media

The monitor and electronic controller are the main components of the electronic control system. The monitor and electronic controller have a self diagnostic function. Self diagnostic checks of the monitor, electronic controller, and the communication line between them are the first steps when troubleshooting the problem(s) in the electronic system. For troubleshooting the electronic control systems, refer to the module Engine And Pump Electronic Control System, Systems Operation, Testing And Adjusting, Form No. SENR6155.

Action alarm indicators on the monitor panel, alert an operator to a problem in the electronic system. The controller service program "Data Mode" can also be used to identify the problems. If the service program is activated during machine operation, problem(s) that are monitored by the monitoring system are

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

indicated on the character display. If the service program is activated when the machine operation is stopped, all existing problems and past problems (problems that have not been corrected) are indicated on the character display. To activate the controller service program "Data Mode", refer to the module Engine And Pump Electronic Control System, Systems Operation, Testing And Adjusting, Form No. SENR6155, "Data Mode" section.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ indicated on the character display. If the service program

If the electronic power unit control system display indicates it is operating correctly, then do operational tests. Operate the machine, following the procedures described in the section "Testing And Adjusting". Compare the results of the operational tests with specifications to determine the extent of the trouble. In operational tests, it is important to determine whether or not enough hydraulic force or implement speed is a problem that extends over the entire machine or with only a specific operation.

If there are any faults in the circuits between the main or pilot pumps and the control valves, the overall performance of the machine will decrease. This type of problem in the hydraulic system is not detected by the self diagnostic functions of the electronic control system described above (no action alarm indication on character display.). To detect such a problem, it is necessary to check the flow characteristics of the pumps, the main relief pressure, pilot pressure, etc.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ indicated on the character display. If the service program
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ indicated on the character display. If the service program

(Hyd #1)

Hydraulic Oil Supply

Reference: Refer to "Operation And Maintenance Manual", Form No. SEBU6727.

(Hyd #2)

Suction Filter Clean Up

Reference: Refer to "Operation And Maintenance Manual", Form No. SEBU6727.

(Hyd #3)

Pressure And Flow Adjustment

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

(Hyd #3-1)

Pilot Pressure Check And Pilot Relief Valve Adjustment

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

(Hyd #3-2)

Check And Adjustment Of Delivery Pressure

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

(Hyd #3-3)

Replacement Of Differential Relief Valve

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

(Hyd #3-4)

Replacement Of Main Relief Valve

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

(Hyd #3-5)

Check And Adjustment Of Line Relief Valve Pressure

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

(Hyd #3-6)

Check And Adjustment Of Swing Relief Valve Pressure

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

(Hyd #3-7)

Check And Adjustment Of Travel Crossover Relief Valve Pressure

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pressure Adjustment".

(Hyd #3-8)

Main Pump Flow Adjustment

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pump Flow Test".

(Hyd #3-9)

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

Swing Pump Flow Adjustment

Reference: Refer to the section in this module, "Testing And Adjusting, Hydraulic System, Pump Flow Test".

(Hyd #4)

Pilot Pressure Check At Main Control Valve Inlet

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Swing Pump Flow Adjustment Reference: Refer to the section

Main Control Valve Compartment (1) Pilot line (bucket close). (2) Pilot line (stick in). (3) Pilot line (boom raise). (4) Pilot line (reverse left travel). (5) Pilot line (reverse right travel). (6) Main control valves.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Swing Pump Flow Adjustment Reference: Refer to the section

Main Control Valve (Viewed From Rear) (7) Pilot line (forward right travel). (8) Pilot line (forward left travel). (9) Pilot line (boom lower). (10) Pilot line (stick out). (11) Pilot line (bucket open).

To check the pilot oil pressure at the inlet of each valve of the main control valves, connect a tee between each pilot line and its control valve.

Attach a 4900 kPa (700 psi) pressure gauge to the tee.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

(Hyd #5)

Pilot Oil Pressure Check At Swing Control Valve Inlet

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (Hyd #5) Pilot Oil Pressure Check At Swing Control

In Front Of Main Control Valves (12) Pilot line (left swing). (13) Swing control valve. (14) Pilot line (right swing).

Connect a tee between pilot lines (12) and (13) and the swing control valve.

Attach a 4900 kPa (700 psi) pressure gauge to the tee.

(Hyd #6)

Swing Motor Performance Problem

To check the swing motor performance, measure the amount of swing motor case drain oil.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (Hyd #5) Pilot Oil Pressure Check At Swing Control
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (Hyd #5) Pilot Oil Pressure Check At Swing Control

Swing Motor (15) Drain hose.

  • 1. Disconnect drain hose (15) from the tee on the swivel.

  • 2. Install a cap in the opening of the tee.

  • 3. Put the open end of the drain hose into a suitable measuring container.

  • 4. With the swing lock pin in the LOCKED position, operate the swing control for one minute.

  • 5. Measure the amount of swing motor case drain oil.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

NOTE: The maximum acceptable case drain oil with a swing relief pressure setting of 27 500 +490 -980 kPa (4500 +72 -140 psi) must be:

For a New swing motor

...

30 liter/min (7.9 U.S. gpm)

For a Rebuilt swing motor

...

34.5 liter/min (9.1 U.S. gpm)

(Hyd #7)

Travel Motor Performance Problem

To check the travel motor performance, measure the amount of case drain oil.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: The maximum acceptable case drain oil with a
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: The maximum acceptable case drain oil with a

Travel Motor (Left Track) (16) Connector. (17) Drain hose.

To measure case drain oil, do the following:

  • 1. Disconnect drain hose (17) from connector (16).

  • 2. Connect a hose to connector (16).

  • 3. Put the other end of the hose into a measuring container.

  • 4. With the track blocked, operate the travel control for one minute.

  • 5. Measure the amount of case drain.

NOTE: The maximum acceptable case drain with a main relief pressure of 34 300 ± 490 kPa (5000 ± 72 psi) must be:

For a NEW travel motor

...

30 liter/min (7.9 U.S. gpm)

For a REBUILT travel motor

...

34.5 liter/min (9.1 U.S. gpm)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: The maximum acceptable case drain oil with a

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Hydraulic oil pressure can remain in the hydraulic systems

Hydraulic oil pressure can remain in the hydraulic systems on this machine after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to section, Release Of Pressure In The Hydraulic System, before any fitting, hose or component is loosened, tightened, removed or adjusted.

When possible, the bucket must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that boom, stick and bucket have correct support.

Swing lock must be engaged before service is started.

Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made.

During diagnosis of the hydraulic system, remember that correct oil temperature, flow, and pressure are necessary for correct operation. Pump output (oil flow) is a function of engine speed (rpm). Oil pressure is caused by resistance to the flow of oil.

Each of the implement circuits has a load check valve to prevent cylinder drift during spool movement. Each circuit also has makeup valves for flow of oil to both ends of the cylinders and motors and there is a line relief valve for each of the cylinder and swing motor circuits.

Visual checks and measurements are the first steps when troubleshooting a possible problem. Next, do the Checks During Operation, and last, do the required checks and adjustments on the machine.

Use a stopwatch, a magnet and a mm (inch) ruler for the following basic checks.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Hydraulic oil pressure can remain in the hydraulic systems

A visual inspection of the system is the first step when troubleshooting a problem. Make the inspection with the engine off and the implements lowered to the ground.

  • 1. Check the oil level in the hydraulic tank. Slowly loosen the hydraulic tank air vent plug and release the

pressure before the filler cap is removed.

  • 2. Remove the filter element and check it for material that would give an indication of damage to a

component.

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

  • 4. Inspect control linkage for bent, broken, or damaged components.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Hydraulic oil pressure can remain in the hydraulic systems

The checks during operation can be used to find leakage in the system. They can also be used to find a

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

valve, pump, motor, or cylinder that is not working correctly. The speed of rod movement or the torque on a motor can be used to check the condition of the cylinders, motors, and the pumps.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ valve, pump, motor, or cylinder that is not working

NOTE: For specifications given in Operational Tests, a NEW specification is the performance that can be expected of a new machine. A REBUILD specification is the performance target to use after rebuilding the components of a system. A machine that performs beyond SERVICE LIMIT specifications should be checked for improper maintenance or adjustment, component wear, or failure.

Specifications given in charts are for a machine equipped with 4600 mm (15 ft) boom, 3500 mm (11 ft 5 in) stick and SAE 5.2 m 3 (6-3/4 yd 3 ) bucket.

NOTE: The power mode selector switch must be placed at Mode III position, unless otherwise specified, during tests.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ valve, pump, motor, or cylinder that is not working
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ valve, pump, motor, or cylinder that is not working
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ valve, pump, motor, or cylinder that is not working

Conditions for the following tests are as follows:

  • 1. Engine speed: No load high idle, 1860 ± 50 rpm

  • 2. Hydraulic oil temperature: 55 ± 5°C (130 ±

NOTE: Fully move the stick in and out several times until the normal hydraulic oil temperature is reached.

  • 3. Delivery pressure settings:

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

  • 31 400 ± 490 kPa (4550 ± 72 psi) For implements

  • 34 300 ± 490 kPa (5000 ± 72 psi) For travel

    • 4. Travel crossover relief valve pressure setting:

      • 36 300 ± 980 kPa (5250 ± 140 psi) For travel test

        • 5. Swing relief valve pressure setting:

          • 30 900 +490 -980 kPa (4500 +72 -140 psi) For swing test

            • 6. Line relief valve pressure setting:

              • 33 300 ± 980 kPa (4850 ± 140 psi) For cylinder test

                • 7. Margin pressure setting:

1960 ± 100 kPa (285 ± 14 psi)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 31 400 ± 490 kPa (4550 ± 72 psi)
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 31 400 ± 490 kPa (4550 ± 72 psi)

Test Preparation:

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 31 400 ± 490 kPa (4550 ± 72 psi)
  • 1. Travel test ground must be hard and as level as possible, and at least 25 m (82.5 ft) long.

  • 2. Draw a 25 m (82.5 ft) straight line on the travel test ground as a reference line.

  • 3. Position one track in line (parallel) with the reference line. Put the machine in the travel test position as

shown in the illustration.

  • 4. The bucket must be empty.

Test Procedure:

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

  • 1. Start the engine and place the power mode selector switch in Mode III position. Place the engine speed

dial at position "10" and the travel speed switch in HIGH (rabbit) position. Move the machine by

operating both travel levers at the same time.

  • 2. The first 5 m (16.5 ft) are for a pre liminary run. Measure the time required for the machine to travel the

remaining 20 m (66 ft) in each direction (FORWARD and REVERSE).

  • 3. Measure the deviation from the reference line.

  • 4. Repeat the above procedure with the travel speed switch in the LOW (turtle) position.

NOTE: The following chart represents the time (in seconds) it should take to complete the 20 m (66 ft) test run:

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Start the engine and place the power mode

NOTE: The following chart represents the travel deviation from the reference line:

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Start the engine and place the power mode
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Start the engine and place the power mode

NOTE: If suitable ground (as stated in Step No. 1 in "Test Conditions" for Travel Test on Level Ground) cannot be found, the following test should be done as a substitute:

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Start the engine and place the power mode

Test Preparation:

  • 1. Place the machine on level ground.

Test Procedure:

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Raise a track for the test as shown
  • 1. Raise a track for the test as shown in the illustration.

  • 2. Put a mark on a shoe of the raised track.

  • 3. Run the raised track with the engine speed dial at high idle (position "10") and the travel speed switch

in HIGH (rabbit sign).

  • 4. Measure the time required for the track to make three complete turns (revolutions) in each direction

(FORWARD and REVERSE).

  • 5. Repeat the above procedure with the travel speed switch in LOW (turtle sign) position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Raise a track for the test as shown
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Raise a track for the test as shown
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Raise a track for the test as shown

Measuring the amount of drift of the machine on a slope will determine if there is a need to check the travel brake.

Test Preparation:

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Place the machine on a slope of 12°.
  • 1. Place the machine on a slope of 12°. The slope surface must be hard and smooth.

  • 2. Put the implements in the position as shown in the illustration.

  • 3. Bucket should be empty.

Test Procedure:

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Place the machine on a slope of 12°.
  • 1. Put marks on both track and ground to indicate its relative position to the slope.

  • 2. Stop the engine and time three minutes (using a stopwatch).

  • 3. Measure the distance the tracks have moved on the slope.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Place the machine on a slope of 12°.
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Place the machine on a slope of 12°.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Measuring the swing speed and over swing of the

Measuring the swing speed and over swing of the machine will determine if there is a need to check the swing motor and/or anti-reaction valve.

Test Preparation:

  • 1. Place the machine on level ground as shown in the illustration.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Measuring the swing speed and over swing of the
  • 2. Put marks on both inner and outer races of the swing bearing to indicate relation of two positions.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Measuring the swing speed and over swing of the
  • 3. The bucket should be empty.

Test Procedure (Speed):

  • 1. Start the engine and place the power mode selector switch in power Mode III position. Place the engine

speed dial at position "10" (high idle).

  • 2. Move the swing control lever to the RIGHT or LEFT until the machine completes three revolutions.

Start the measurement after the upper structure has rotated one full revolution. Return the swing control lever to the NEUTRAL position at the end of the swing operation and measure the amount of over swing by measuring the distance between the marks on the swing bearing.

NOTE: Use a reference point that is visible from the operator's seat as a indicator of when to stop the rotation.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Procedure (Over Swing): 1. Move the swing control

Test Procedure (Over Swing):

  • 1. Move the swing control lever to the LEFT or RIGHT and measure the amount of over swing after a

complete 180° swing operation.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Procedure (Over Swing): 1. Move the swing control

Test Procedure (Speed):

  • 1. Move the swing control lever to the LEFT or RIGHT and measure the amount of over swing after a

complete 180° swing operation.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Procedure (Over Swing): 1. Move the swing control
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Procedure (Over Swing): 1. Move the swing control
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Procedure (Over Swing): 1. Move the swing control

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

Test Preparation:

  • 1. Place the machine on a 12° slope.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Put the implements to maximum reach and fill
  • 2. Put the implements to maximum reach and fill the bucket with soil. The bucket should be positioned

above the ground to clear any obstructions.

Test Procedure (Speed):

  • 1. Put positional marks on the inner and outer races of the swing bearing. Place the upper structure at a

90° angle to the tracks.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Put the implements to maximum reach and fill
  • 2. Measure the time needed to swing the upper structure 90° counterclockwise up hill. Do the same for a

90° turn clockwise up hill.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Put the implements to maximum reach and fill

Test Procedure (Drift):

  • 1. Stop the machine on a 12° slope. Place the upper structure at a 90° angle to the lower structure as

shown in the illustration.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Put marks on inner and outer races of
  • 2. Put marks on inner and outer races of the swing bearing.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Put marks on inner and outer races of
  • 3. Stop the engine.

  • 4. Leave the machine in this position for three minutes, and measure swing drift on the circumference of

the swing bearing.

  • 5. Rotate the upper structure 180° from the original position as described in Step 1.

  • 6. Repeat Steps 2 through 4.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Put marks on inner and outer races of
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Put marks on inner and outer races of

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Preparation: 1. Place the machine on level ground

Test Preparation:

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Preparation: 1. Place the machine on level ground
  • 1. Place the machine on level ground as shown in the illustration. Set engine speed to high and increase

the hydraulic oil to normal operating temperature.

  • 2. Fill the bucket with soil to approximately 6300 kg (13,860 lb).

Test Procedure (For Boom And Stick Cylinders):

  • 1. Fully extend the bucket cylinder.

  • 2. Fully retract the stick cylinder.

  • 3. Raise the boom until its upper surface becomes parallel to the ground.

  • 4. Measure each cylinder's length from pin to pin.

  • 5. Leave the machine in this position for three minutes, then measure each cylinder's length from pin to

pin for drift.

Test Procedure (For Bucket Cylinder):

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Fully extend the bucket cylinder. 2. Raise the
  • 1. Fully extend the bucket cylinder.

  • 2. Raise the boom high enough until the stick is perpendicular to the ground and stop the engine.

  • 3. Measure the bucket cylinder's length from pin to pin.

  • 4. Stop the engine.

  • 5. Leave the machine in this position for three minutes the measure the bucket cylinder's length from pin

to pin for drift.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Fully extend the bucket cylinder. 2. Raise the
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Fully extend the bucket cylinder. 2. Raise the
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Fully extend the bucket cylinder. 2. Raise the

Test Preparation:

  • 1. Place the machine on level ground.

  • 2. The bucket must be empty.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

Test Procedures (Boom Cylinders):

  • 1. Fully retract the bucket and stick cylinders.

Extension Test;

Measure the time required for the boom cylinders to reach full extension position starting with the bucket on ground.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Test Procedures (Boom Cylinders): 1. Fully retract the bucket

Retraction Test;

Measure the time required for the bucket to come in contact with the ground from the full extension position of boom cylinders.

Test Procedure (Stick Cylinder):

  • 1. Position the upper surface of the boom parallel to the ground and fully extend the bucket cylinder.

Extension Test;

Measure the time required for the stick cylinder to reach full extension position from full retraction position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Retraction Test; Measure the time required for the stick

Retraction Test;

Measure the time required for the stick cylinder to reach full retraction position from full extension position.

Test Procedure (Bucket Cylinder)

1. Position the upper surface of the boom parallel and the stick perpendicular to the ground.

Extension Test;

Measure the time required for the bucket cylinder to reach full extension position from full retraction position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Retraction Test; Measure the time required for the stick

Retraction Test;

Measure the time required for the bucket cylinder to reach full retraction position from full extension position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Release the pressure in the implement hydraulic circuits (boom,
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Release the pressure in the implement hydraulic circuits (boom,

Release the pressure in the implement hydraulic circuits (boom, stick, and bucket) before any hydraulic lines or components are disconnected or removed.

  • 1. Fully retract the rod in the stick cylinder.

  • 2. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.

  • 3. Lower the boom until the bucket is flat on the ground.

  • 4. Shut off the engine and put the hydraulic activation control lever in the UNLOCK position.

  • 5. Move the control levers for boom, bucket, stick, and swing full strokes. This will relieve any pressure

that might be present in the pilot system.

  • 6. Slowly loosen the air vent plug on the hydraulic tank and release the pressure.

  • 7. Tighten the air breather back on the hydraulic tank.

  • 8. The pressure in the system has been released and lines and components can be removed.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Release the pressure in the implement hydraulic circuits (boom,
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Release the pressure in the implement hydraulic circuits (boom,

NOTE: A new or rebuilt machine must perform according to NEW or REBUILD specifications. A machine that performs beyond SERVICE LIMIT specifications must be checked for improper adjustment, wear or damage of relief valves or pumps.

(6XK1-114)

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Schematic Of Hydraulic System Components (1) Rear pump. (2)

Schematic Of Hydraulic System Components (1) Rear pump. (2) Differential pressure relief valve (rear pump). (3) Travel motor (right). (4) Main control valves. (5) Boom drift reduction valve. (6) Front swing motor. (7) Rear swing motor. (8) Differential pressure relief valve (front pump). (9) Fr ont pump. (10) Pilot oil manifold. (11) Travel motor (left).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Schematic Of Hydraulic System Components (1) Rear pump. (2)

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: Test and adjustment of main relief valves/differential relief

NOTE: Test and adjustment of main relief valves/differential relief valves are not needed as long as all of the pressures indicated in the above chart are normal.

(8SL1-UP and 6XK115-UP)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: Test and adjustment of main relief valves/differential relief

Schematic Of Hydraulic System Components. (1) Rear pump. (2) Front pump. (3) Right travel motor. (4) Boom drift reduction valve. (5) Differential pressure relief valve (front pump). (6) Differential pressure relief valve (rear pump). (7) Right swing motor. (8) Main control valves. (9) Pilot oil manifold. (10) Left swing motor. (11) Stick drift reduction valve. (12) Left travel motor.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (8SL1-Up and 6XK1-Up) Pressure Variation By Adjusting Screw (6XK1-114)

(8SL1-Up and 6XK1-Up)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (8SL1-Up and 6XK1-Up) Pressure Variation By Adjusting Screw (6XK1-114)
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (8SL1-Up and 6XK1-Up) Pressure Variation By Adjusting Screw (6XK1-114)
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (8SL1-Up and 6XK1-Up) Pressure Variation By Adjusting Screw (6XK1-114)

Pressure Variation By Adjusting Screw (6XK1-114)

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pressure Variation By Adjusting Screw (8SL1-Up and 8XK115-Up) NOTE:

Pressure Variation By Adjusting Screw (8SL1-Up and 8XK115-Up)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pressure Variation By Adjusting Screw (8SL1-Up and 8XK115-Up) NOTE:

NOTE: Values given above are approximate. Use a pressure gauge for adjustment.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pressure Variation By Adjusting Screw (8SL1-Up and 8XK115-Up) NOTE:

Preparation

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pressure Variation By Adjusting Screw (8SL1-Up and 8XK115-Up) NOTE:

Pilot Oil Manifold Compartment (1) Pilot oil manifold. (2) Tap. (3) Screw. (4) Pilot relief valve. (5) Locknut.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

  • 1. Place the machine on level ground and stop the engine.

  • 2. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

  • 3. Connect a 4900 kPa (700 psi) pressure gauge to tap (2) of pilot oil manifold (1).

  • 4. Start the engine and move the stick IN and OUT to its full travel position. Do this operation several

times until the hydraulic oil temperature reaches 55 ± 5°C (131 ± 9°F).

  • 5. Place the power mode selector switch in Mode III position.

  • 6. Place the engine speed dial at position "10". Make sure that engine speed under a no load condition is

1860 ± 50 rpm with AEC switch in the OFF position. (Read rpm 3 seconds after the engine speed dial switch has been placed in position "10".)

NOTE: Normal operations (see characteristic curves) of the engine and pumps are necessary for the pressure adjustments. If the results of the pressure adjustment are not correct, then the engine and pump characteristic curve needs to be checked.

NOTE: Make pressure adjustments in the following sequence.

Adjustment Procedure

  • 1. Loosen locknut (5).

  • 2. Turn screw (3) until the pilot pressure at tap (2) is 3450 + 100 -0 kPa (500 + 14 -0 psi).

  • 3. Tighten locknut (5).

NOTE: Always make final pressure adjustments on pressure rise.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Place the machine on level ground and stop
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 1. Place the machine on level ground and stop

Front Of Main Control Valves (6) Pilot hose. (7) Sequence valve.

  • 1. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

  • 2. Disconnect pilot hose (6) from sequence valve (7).

NOTE: Secure pilot hose (6) from falling down out of reach.

  • 3. Install a plug (11/16 - 16) in the open end of pilot hose (6). Leave the port of sequence valve (7) open

to the atmospheric pressure.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Front Of Main Control Valves (6) Pilot hose. (7)
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Front Of Main Control Valves (6) Pilot hose. (7)

Front Of Main Control Valves (6) Pilot hose. (7) Sequence valve.

  • 1. Remove plug (11/16 - 16) from pilot hose (6).

  • 2. Connect pilot hose (6) to sequence valve (7).

NOTE: Secure pilot hose (6) from falling down out of reach.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Front Of Main Control Valves (6) Pilot hose. (7)
  • 1. Disable sequence valve (7).

Reference: Make reference to "Disabling Sequence Valve".

Preparation

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Front Of Main Control Valves (6) Pilot hose. (7)

Front Of Main Control Valves (6) Pilot hose. (7) Sequence valve.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Front Of Main Control Valves (6) Pilot hose. (7)

Main Pump Compartment (8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure). (10) Pressure gauge. (11) Pressure gauge. (12) Tap (load pressure in boom/travel circuits). (13) Hose. (14) Tap (load pressure in stick/bucket/attachment circuits). (15) Differential pressure gauge. (16) Hose.

  • 2. To adjust the front pump, connect hose (13) of differential pressure gauge (1U5796) to tap (9), and hose

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

(16) to tap (12). To adjust the rear pump, connect hose (13) of differential pressure gauge (1U5796) to tap (8) and hose (16) to tap (14).

Adjustment

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (16) to tap (12). To adjust the rear pump,

Main Pump Compartment (17) Locknut (front pump). (18) Screw (front pump). (19) Locknut (rear pump). (20) Screw (rear pump).

  • 1. To adjust the front pump margin pressure:

    • a. With the engine running at high idle and power mode selector in Mode III position, very slowly move the boom control lever to PARTIAL BOOM RAISE position until the boom just starts to move up, and hold the control lever at this position.

NOTE: The margin pressure at pressure gauge (11) will read too low if the boom control lever is moved too fast and will read too high if the lever is moved to slow. Maintain the position of the boom control lever once the boom starts to raise.

  • b. Check to see that pressure gauge (11) reads 1960 ± 100 kPa (285 ± 14 psi).

  • c. If not, loosen locknut (17) and turn screw (18) until pressure gauge (11) reads 1960 ± 100 kPa (285 ± 14 psi). Tighten locknut (17).

  • 2. To adjust the rear pump margin pressure:

    • a. With the engine running at high idle and power mode selector in MODE III position, very slowly

move the stick control lever to PARTIAL STICK IN position until the stick just starts to move in,

and hold the control lever at this position.

  • b. Check to see pressure gauge (11) reads 1960 ± 100 kPa (285 ± 14 psi).

  • c. If not, loosen locknut (19) and turn screw (20) until pressure gauge (11) reads 1960 ± 100 kPa (285 ± 14 psi). Tighten locknut (19).

  • 3. After pressure adjustment, reconnect pilot hose (6) to sequence valve (7).

NOTE: Pressure gauge (10) reads the main pump delivery pressure setting.

NOTE: Main pump delivery pressure varies with a change in margin pressure. After adjustment of main pump margin pressure, be sure to readjust the delivery pressure in accordance with "Adjustment Of Delivery Pressure" given later.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (16) to tap (12). To adjust the rear pump,
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (16) to tap (12). To adjust the rear pump,

Preparation

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump Compartment (10) Crossover load signal hose. (11)

Main Pump Compartment (10) Crossover load signal hose. (11) Load signal hose from main control valve. (12) Front pump differential relief valve hose. (13) Rear pump system pressure test port. (14) Rear pump load signal pressure test port.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump Compartment (10) Crossover load signal hose. (11)

Main Pump Compartment (10) Crossover load signal hose. (16) Rear pump differential relief valve hose. (19) Front pump system pressure test port.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump Compartment (10) Crossover load signal hose. (11)

Main Control Valve Compartment (8) Boom raise pilot line.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration of Tool Layout 1 (Boom Raise Pilot Line)

Illustration of Tool Layout 1 (Boom Raise Pilot Line) (20) Pressure gauge. (21) Nipple. (22) Coupler. (23) Hose. (24) Nipple. (25) Seal. (26) Seal.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration of Tool Layout 2 (Front Pump Pressure Gauge

Illustration of Tool Layout 2 (Front Pump Pressure Gauge Connection) (27) Nipple. (28) Seal. (29) Seal. (30) Tee. (31) Differential Pressure Gauge. (32) Tee. (33) Cap.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration of Tool Layout 3 (Rear Pump Pressure Gauge

Illustration of Tool Layout 3 (Rear Pump Pressure Gauge Connection) (29) Seal. (31) Differential Pressure Gauge. (32) Tee.

  • 1. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

  • 2. Connect pressure gauge into boom raise pilot line (8) in accordance with layout illustration 1.

  • 3. Install necessary tools in accordance with the layout illustration 2 and 3 as follows.

    • a. To adjust the front pump, disconnect crossover load signal hose (10) and rear pump differential

relief valve hose (16). Leave connector open to air. Connect both hoses using nipple, tees and cap.

Connect differential pressure gage to nipple (27) in load signal hose connection and also front pump system pressure tap (19).

  • b. To adjust the rear pump, disconnect crossover load signal hose (10), load signal hose from main

control valve (11) and front pump differential relief valve hose (12). Leave connector open to air. Connect the hoses using tee (32). Connect differential pressure gauge to rear pump load signal pressure tap (14) and rear pump system pressure tap (13).

Adjustment

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump (Top View) (11) Load sensing regulator (front

Main Pump (Top View) (11) Load sensing regulator (front pump). (14) Load sensing regulator (rear pump). (21) Locknut. (22) Screw.

  • 1. To adjust the front pump margin pressure:

    • a. With the engine running at high idle and power mode selector in MODE III position, move the boom control lever to PARTIAL BOOM RAISE position and hold boom activation pressure at 150

psi.

  • b. Check to see that margin pressure gauge reads 1960 ± 100 kPa (285 ± 14 psi).

  • c. If not, loosen locknut (21) of load sensing regulator (11) and turn screw (22) until pressure gauge reads 1960 ± 100 kPa (285 ± 14 psi). Tighten locknut (21).

  • 2. To adjust the rear pump margin pressure:

    • a. With the engine running at high idle and power mode selector in MODE III position, move the boom control lever to PARTIAL BOOM RAISE position and hold boom activation pressure at 150 psi.

    • b. Check to see that margin pressure gauge reads 1960 ± 100 kPa (285 ± 14 psi).

    • c. If not, loosen locknut (21) of load sensing regulator (14) and turn screw (22) until pressure gauge reads 1960 ± 100 kPa (285 ± 14 psi). Tighten locknut (21).

NOTE: Turning screw (22) clockwise increases pressure. Turning screw (22) counterclockwise decreases pressure.

  • 3. After pressure adjustment, reconnect hoses as connected before.

NOTE: Pressure gauge reads the main pump delivery pressure setting.

NOTE: Main pump delivery pressure varies with a change in margin pressure. After adjustment of main pump margin pressure, be sure to readjust the delivery pressure in accordance with "Adjustment Of Main Pump Delivery Pressure" given later.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump (Top View) (11) Load sensing regulator (front

Preparation (6XK1-114)

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump

Main Control Valves (21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief val ve (stick cylinder head end). (24) Signal relief valve (stick/bucket/bottom dump circuits). (25) Signal relief valve (travel circuit). (26) Line relief valve (bottom dump cylinder rod end) (27) Line relief valve (bucket cylinder rod end). (28) Line relief valve (stick cylinder rod end). (29) Signal relief valve (boom circuit). (30) Line relief valve (boom cylinder rod end).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump

Signal Relief Valve (Boom Circuit) (29) Signal relief valve (boom circuit). (31) Locknut. (32) Screw.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Stick, Bucket, Bottom Dump And Travel

Signal Relief Valve (Stick, Bucket, Bottom Dump And Travel Circuits) (24) Signal relief valve (stick, bucket, bottom dump). (25) Signal relief valve (travel). (33) Locknut. (34) Screw.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Stick, Bucket, Bottom Dump And Travel

Main Pump Compartment (8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).

  • 1. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

  • 2. Disconnect pilot hose (6) from sequence valve (7).

NOTE: Secure pilot hose (6) from falling down out of reach.

  • 3. Install a plug (11/16-16) in the open end of pilot hose (6). Leave the port of sequence valve (7) open to

the atmospheric pressure.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Stick, Bucket, Bottom Dump And Travel

Front Of Main Control Valves (6) Pilot hose. (7) Sequence valve.

  • 4. Loosen locknut (31) of signal relief valve (29) and tighten screw (32) 1/2 turn. Tighten locknut (31).

  • 5. Loosen locknut (33) of signal relief valves (24) and (25) and tighten screw (34) one turn. Tighten

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

locknut (33).

  • 6. Attach 49 000 kPa (7100 psi) pressure gauge to tap (8) or (9). Tap (8) is for the rear pump. Tap (9) is

for the front pump.

  • 7. Place the power mode selector switch in Mode III position. Place the engine speed dial at position "2".

Preparation (8SL1-Up and 6XK115-Up)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ locknut (33). 6. Attach 49 000 kPa (7100 psi)

Main Control Valves (21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief val ve (stick cylinder head end). (24) Signal relief valve (boom/stick/bucket/bottom dump circuits). (25) Signal relief valve (travel circuit). (26) Line relief valve (bottom dump cylinder rod end) (27) Line relief valve (bucket cylinder rod end). (28) Line relief valve (stick cylinder rod end). (30) Line relief valve (boom cylinder rod end).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Boom, Stick, Bucket, Bottom Dump Circuits)

Signal Relief Valve (Boom, Stick, Bucket, Bottom Dump Circuits) (24) Signal relief valve (boom circuit). (33) Locknut. (34) Screw.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Boom, Stick, Bucket, Bottom Dump Circuits)

Signal Relief Valve (Travel Circuits) (25) Signal relief valve (travel). (31) Locknut. (32) Screw.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Boom, Stick, Bucket, Bottom Dump Circuits)

Main Pump Compartment (Typical Example) (8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).

1. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic System".

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

  • 2. Loosen locknut (31) of signal relief valve (25) and tighten screw (32) 1/2 turn. Tighten locknut (31).

  • 3. Loosen locknut (33) of signal relief valve (24) and tighten screw (34) one turn. Tighten locknut (33).

  • 4. Attach 49 000 kPa (7100 psi) pressure gauge to tap (8) or (9). Tap (8) is for the rear pump. Tap (9) is

for the front pump.

  • 5. Place the power mode selector switch in Mode III position. Place the engine speed dial at position "2".

Boom, Stick, And Bucket Line Relief Valve Adjustment Procedure (8SL1-Up and

6XK1-Up)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Loosen locknut (31) of signal relief valve (25)

On Boom Base (35) Boom drift reduction valve. (36) Line relief valve (boom cylinder head end). (37) Locknut. (38) Cap.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Loosen locknut (31) of signal relief valve (25)

Line Relief Valve (37) Locknut. (38) Cap. (39) Screw.

  • 1. Fully operate the boom, stick and bucket controls and read the pressure gauge attached at tap (8) or (9)

to check each of the following line relief valves:

  • a. Boom cylinder head end (36).

  • b. Boom cylinder rod end (30). If an appropriate location is not available for full retraction of

the boom cylinder, reverse the boom line relief valves of the head end and rod end.

  • c. Stick cylinder head end (23).

  • d. Stick cylinder rod end (28).

  • e. Bucket cylinder head end (22).

  • f. Bucket cylinder rod end (27).

  • g. Bottom dump cylinder head end (21).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

h. Bottom dump cylinder rod end (26). Attach 49 000 kPa (7100 psi) pressure gauge at tap (9) for checking line relief valves (36) and (30). Attach the pressure gauge at tap (8) for adjusting line relief valves (23), (28), (22), (21), (26), and (27).

  • 2. If a pressure gauge reading is not 33 300 ± 980 kPa (4850 ± 140 psi), adjust the line relief pressure as

follows:

  • a. Remove cap (38).

  • b. Loosen locknut (37) and turn screw (39) until the pressure gauge reads 33 300 ± 980 kPa (4850 ±

140 psi). Turning screw (39) clockwise increases the pressure. Turning screw (39) counterclockwise

decreases pressure.

  • c. Tighten locknut (37) and then install cap (38).

  • 3. Adjust signal relief valves (24) and (25).

Reference: Make reference to the section "Adjusting Of Main Pump Delivery Pressure".

  • 4. After pressure adjustment, reconnect pilot hose (6) to sequence valve (7) (6XK1-114).

Travel Motor Crossover Relief Valve Pressure Adjustment Procedure (8SL1-Up and

6XK1-Up)

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ h. Bottom dump cylinder rod end (26). Attach 49

Travel Brake Valve (Left Track) (40) Adjuster. (41) Locknut. (42) Crossover relief valve (reverse travel). (43) Locknut. (44) Adjuster. (45) Crossover relief valve (forward travel).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ h. Bottom dump cylinder rod end (26). Attach 49

Crossover Relief Valve (40) Adjuster. (41) Locknut. (43) Locknut. (44) Adjuster.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sprocket (Left Track) (46) Sprocket. (47) Stopper. Signal Relief

Sprocket (Left Track) (46) Sprocket. (47) Stopper.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sprocket (Left Track) (46) Sprocket. (47) Stopper. Signal Relief

Signal Relief Valve (Stick, Bucket, Bottom Dump And Travel Circuits) (25) Signal relief valve (travel). (31) Locknut. (32) Screw.

Preparation

  • 1. Loosen locknut (31) of signal relief valve (25) and tighten screw (32) one turn. Tighten locknut (31).

  • 2. Block forward left travel by putting stopper (47) in position on the gear of sprocket (46), as shown

above.

NOTE: Run the engine at low idle and slowly move the left travel control lever to PARTIAL FORWARD position to secure stopper (47) in sprocket (46).

  • 3. Run the engine with the engine speed dial switch at position "10", the travel speed switch at LOW

(tortoise) position, and the power mode selector switch at Mode III position.

Adjustment

  • 1. Slowly move the left travel control lever to FULL FORWARD position and check the pressure of

crossover relief valve (45) by reading the pressure gauge attached at tap (9).

To adjust crossover relief valve (45), loosen locknut (43) and turn adjuster (44) until the pressure gauge (10) at tap (9) reads 36 300 ± 980 kPa (5250 ± 140 psi). Tighten locknut (43).

NOTE: One revolution of adjuster (44) is equivalent to approximately 9655 kPa (1400 psi) change in pressure.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

  • 2. Position stopper (47) to block reverse left travel.

Reference: Turning adjuster (40) or (44) clockwise increases the pressure. Turning adjuster (40) or (44) counterclockwise decreases the pressure.

NOTE: Run the engine at low idle and slowly move the left travel control lever to PARTIAL REVERSE position to secure stopper (47) in sprocket (46).

  • 3. Slowly move the left travel control lever to FULL REVERSE position and check the pressure of

crossover relief valve (42) by reading the pressure gauge attached at tap (9).

To adjust crossover relief valve (42), loosen locknut (41) and turn adjuster (40) until the pressure gauge (10) at tap (9) reads 36 300 ± 980 kPa (5250 ± 140 psi). Tighten locknut (41).

NOTE: One revolution of adjuster (40) is equivalent to approximately 9655 kPa (1400 psi) change in pressure.

  • 4. Adjust the pressure of crossover relief valves of the right travel motor in the same manner as described

for the left travel motor crossover relief valves.

  • 5. Adjust signal relief valve (25) to the correct setting. See the section, "Adjustment Of Main Pump

Delivery Pressure".

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Position stopper (47) to block reverse left travel.

NOTE: Main pump delivery pressure setting is set by adjusting each of the signal relief valves. Run engine at high idle with power mode selector switch set at MODE III position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Position stopper (47) to block reverse left travel.

Main Control Valves

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

(21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief val ve (stick cylinder head end). (24) Signal relief valve (stick/bucket/bottom dump circuits). (25) Signal relief valve (travel circuit). (26) Line relief valve (bottom dump cylinder rod end) (27) Line relief valve (bucket cylinder rod end). (28) Line relief valve (stick cylinder rod end). (29) Signal relief valve (boom circuit). (30) Line relief valve (boom cylinder rod end).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (21) Line relief valve (bottom dump cylinder head end).

In Front Of Main Control Valves (6) Pilot hose. (7) Sequence valve.

  • 1. Release the pressure in the hydraulic system.

Reference: Make reference to the section "Release Of Pressure In The Hydraulic System".

  • 2. Disconnect pilot hose (6) from sequence valve (7).

NOTE: Secure pilot hose (6) from falling down out of reach.

  • 3. Install a plug (11/16-16) in the open end of pilot hose (6). Leave the port of sequence valve (7) open to

the atmospheric pressure.

  • 4. To adjust the front pump delivery pressure;

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (21) Line relief valve (bottom dump cylinder head end).

Sprocket (Left Track) (46) Sprocket. (47) Stopper.

a. Block forward left travel by putting stopper (47) in position on the gear of left track sprocket (46), as shown above. Slowly move the left travel control lever to FULL FORWARD position and check the delivery pressure of the front pump by reading the pressure gauge attached at tap (9).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ (21) Line relief valve (bottom dump cylinder head end).

Main Pump Compartment (8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Stick, Bucket, Bottom Dump, And Travel

Signal Relief Valve (Stick, Bucket, Bottom Dump, And Travel Circuits) (24) Signal relief valve (stick, bucket, bottom dump). (25) Signal relief valve (travel). (33) Locknut. (34) Screw.

NOTE: To adjust the delivery pressure, loosen locknut (33) of signal relief valve (25) and turn screw (34) until the pressure gauge at tap (9) reads 34 300 ± 490 kPa (5000 ± 72 psi). Tighten locknut (33).

  • b. Slowly move the boom control lever to boom FULL RAISE position and check the delivery

pressure of the front pump by reading the pressure gauge attached at tap (9).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Stick, Bucket, Bottom Dump, And Travel

Signal Relief Valve (Boom Circuit) (29) Signal relief valve (boom circuit). (31) Locknut. (32) Screw.

NOTE: To adjust the delivery pressure, loosen locknut (31) of signal relief valve (29) and turn screw (32) until the pressure gauge at tap (9) reads 31 400 ± 490 kPa (4550 ± 72 psi). Tighten locknut (31).

Reference: Turning screw (33) or (32) clockwise increases the pressure. Turning screw (33) or (32) counterclockwise decreases the pressure.

5. To adjust the delivery pressure of the rear pump;

  • a. Slowly move the stick control lever to stick FULL IN position and check the delivery pressure of the rear pump by reading the pressure gauge at tap (8).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

NOTE: To adjust the delivery pressure, loosen locknut (33) of signal relief valve (24) and turn screw (34) until the pressure gauge at tap (8) reads 31 400 ± 490 kPa (4550 ± 72 psi). Tighten locknut (33).

  • 6. After pressure adjustment, reconnect pilot hose (6) to sequence valve (7).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: To adjust the delivery pressure, loosen locknut (33)
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: To adjust the delivery pressure, loosen locknut (33)

NOTE: Main pump delivery pressure setting is set by adjusting each of the signal relief valves. Run engine at high idle with power mode selector switch set at MODE III position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: To adjust the delivery pressure, loosen locknut (33)

Main Control Valves (21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief val ve (stick cylinder head end). (24) Signal relief valve (boom/stick/bucket/bottom dump circuits). (25) Signal relief valve (travel circuit). (26) Line relief valve (bottom dump cylinder rod end) (27) Line relief valve (bucket cylinder rod end). (28) Line relief valve (stick cylinder rod end). (30) Line relief valve (boom cylinder rod end).

  • 1. Release the pressure in the hydraulic system.

Reference: Make reference to the section "Release Of Pressure In The Hydraulic System".

  • 2. To adjust the front pump delivery pressure;

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sprocket (Left Track) (46) Sprocket. (47) Stopper. a. Block

Sprocket (Left Track) (46) Sprocket. (47) Stopper.

  • a. Block forward left travel by putting stopper (47) in position on the gear of left track sprocket (46), as shown above. Slowly move the left travel control lever to FULL FORWARD position and

check the delivery pressure of the front pump by reading the pressure gauge attached at tap (9).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sprocket (Left Track) (46) Sprocket. (47) Stopper. a. Block

Main Pump Compartment (Typical Example) (8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sprocket (Left Track) (46) Sprocket. (47) Stopper. a. Block

Signal Relief Valve (Stick, Bucket, Bottom Dump, And Travel Circuits) (24) Signal relief valve. (33) Locknut. (34) Screw.

NOTE: To adjust the delivery pressure, loosen locknut (33) of signal relief valve (24) and turn screw (34) until the pressure gauge at tap (9) reads 34 300 ± 490 kPa (5000 ± 72 psi). Tighten locknut (33).

  • b. Slowly move the boom control lever to boom FULL RAISE position and check the delivery

pressure of the front pump by reading the pressure gauge attached at tap (9).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Boom Circuit) (25) Signal relief valve

Signal Relief Valve (Boom Circuit) (25) Signal relief valve (boom circuit). (31) Locknut. (32) Screw.

NOTE: To adjust the delivery pressure, loosen locknut (31) of signal relief valve (25) and turn screw (32) until the pressure gauge at tap (9) reads 31 400 ± 490 kPa (4550 ± 72 psi). Tighten locknut (31).

Reference: Turning screw (33) or (32) clockwise increases the pressure. Turning screw (33) or (32) counterclockwise decreases the pressure.

5. To adjust the delivery pressure of the rear pump;

a. Slowly move the stick control lever to stick FULL IN position and check the delivery pressure of the rear pump by reading the pressure gauge at tap (8).

NOTE: To adjust the delivery pressure, loosen locknut (33) of signal relief valve (24) and turn screw (34) until the pressure gauge at tap (8) reads 31 400 ± 490 kPa (4550 ± 72 psi). Tighten locknut (33).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Boom Circuit) (25) Signal relief valve
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Boom Circuit) (25) Signal relief valve
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Signal Relief Valve (Boom Circuit) (25) Signal relief valve

Main Pump Compartment (48) Differential relief valve (front pump). (49) Differential relief valve (rear pump).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (50) Main relief valve (in right

Main Control Valves (50) Main relief valve (in right body). (51) Main relief valve (in left body).

NOTE: Check and/or adjustment of differential relief valves and main relief valves is not needed as long as all of the pressures checked in the previous procedures are normal. Use a new differential relief valve and/or main relief valve for replacement when the following problems occur:

1. The pump delivery pressure is normal, but all of the pressures of the line relief valves (30), (36), left travel crossover relief valves (42), (45) and right travel crossover relief valves are too low.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump

Main Control Valves (21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief val ve (stick cylinder head end). (24) Signal relief valve (stick/bucket/bottom dump circuits). (25) Signal relief valve (travel circuit). (26) Line relief valve (bottom dump cylinder rod end) (27) Line relief valve (bucket cylinder rod end). (28) Line relief valve (stick cylinder rod end). (29) Signal relief valve (boom circuit). (30) Line relief valve (boom cylinder rod end).

If this problem occurs, first replace differential relief valve (48). If the problem still exists, then replace main relief valve (51).

2. The pump delivery pressure is normal, but all of the pressures of line relief valves (21), (22), (23), (26), (27), and (28) are too low.

If this problem occurs, first replace differential relief valve (49). If the problem still exists, then replace main relief valve (50).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump

Main Pump Compartment (Typical Example) (48) Differential relief valve (front pump). (49) Differential relief valve (rear pump).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (50) Main relief valve (in right

Main Control Valves (50) Main relief valve (in right body). (51) Main relief valve (in left body).

NOTE: Check and/or adjustment of differential relief valves and main relief valves is not needed as long as all of the pressures checked in the previous procedures are normal. Use a new differential relief valve and/or main relief valve for replacement when the following problems occur:

1. The pump delivery pressure is normal, but all of the pressures of the line relief valves (30), (36), left travel crossover relief valves (42), (45) and right travel crossover relief valves are too low.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump

Main Control Valves (21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief val ve (stick cylinder head end). (24) Signal relief valve (boom/stick/bucket/bottom dump circuits). (25) Signal relief valve (travel circuit). (26) Line relief valve (bottom dump cylinder rod end) (27) Line relief valve (bucket cylinder rod end). (28) Line relief valve (stick cylinder rod end). (30) Line relief valve (boom cylinder rod end).

If this problem occurs, first replace differential relief valve (48). If the problem still exists, then replace main relief valve (51).

2. The pump delivery pressure is normal, but all of the pressures of line relief valves (21), (22), (23), (26), (27), and (28) are too low.

If this problem occurs, first replace differential relief valve (49). If the problem still exists, then replace main relief valve (50).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valves (21) Line relief valve (bottom dump

NOTE: There are two procedure options for adjustment of the sequence valve.

Adjustment Procedure Option 1

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Tool Layout (For Sequence Valve Pressure Test)
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Tool Layout (For Sequence Valve Pressure Test)

Illustration Of Tool Layout (For Sequence Valve Pressure Test) (52) Connector (pilot on main control valves). (53) O-ring. (54) Cap. (55) Pilot hose (travel line). (56) Gauge. (57) Elbow (main control valves). (58) Connector. (59) Nipple. (60) O-ring. (61) Swivel tee. (62) Elbow (main control valves. (63) Pilot hose (stick line).

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valve Compartment (52) Connector (pilot on main

Main Control Valve Compartment (52) Connector (pilot on main control valves). (55) Pilot hose (travel line). (62) Elbow. (63) Pilot hose.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valve Compartment (52) Connector (pilot on main

Main Pump Compartment (8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).

 

Preparation

1.

Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

2.

Disconnect pilot hose (63) from elbow (62).

3.

Connect swivel tees (61) to elbow (62).

4.

Connect pilot hose (63) to swivel tee (61).

5.

Connect coupler (57) to swivel tee (61).

6.

Attach 4900 kPa (700 psi) pressure gauge (56) to coupler (57).

7.

Disconnect pilot hose (55) from connector (52). Install cap (54) on connector (52).

8.

Connect pilot hose (55) to swivel tee (61).

9.

Attach a 49 000 kPa (7100 psi) pressure gauge to each of taps (8) and (9). Tap (8) is for the rear pump

and tap (9) is for the front pump.

10. Run the engine at 1860 ± 50 rpm under no load. (Read rpm an elapse of three seconds after the engine speed dial has been placed in position "10".)

Adjustment

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sequence Valve (55) Pilot hose. (63) Pilot hose. (64)

Sequence Valve (55) Pilot hose. (63) Pilot hose. (64) Locknut. (65) Screw.

  • 1. Move the stick control lever IN until the stick cylinder reaches its full extension position. Return the

stick control lever to the NEUTRAL position.

  • 2. Slowly move the stick control lever from the NEUTRAL position toward the stick IN position.

  • 3. Hold the stick control lever at the position where the readings of the pressure gauges at taps (9) and

(10) have just begun to differ from each other.

  • 4. Loosen locknut (64) and turn screw (65) until the total pressure reading of the pressure gauge

connected to coupler (57) is 4900 ± 200 kPa (700 ± 28 psi). Turning screw (65) clockwise, increases the pressure. Turning screw (65) counterclockwise, decreases the pressure.

  • 5. Tighten locknut (64) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).

Adjustment Procedure Option 2

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sequence Valve (55) Pilot hose. (63) Pilot hose. (64)

Main Control Valve Compartment (52) Connector (pilot on main control valves). (55) Pilot hose (travel line). (62) Elbow. (63) Pilot hose.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sprocket (Left Track) (46) Sprocket. (47) Stopper. Preparation 1.

Sprocket (Left Track) (46) Sprocket. (47) Stopper.

 

Preparation

1.

Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

2.

Disconnect pilot hose (63) from elbow (62).

3.

Connect swivel tee (61) between pilot hose (63) and elbow (62).

4.

Connect coupler (57) to swivel tee (61).

5.

Attach 4900 kPa (700 psi) pressure gauge (56) to coupler (57).

6.

Disconnect pilot hose (55) from connector (52).

7.

Install swivel tee (61) between pilot hose (55) and connector (52).

8.

Connect coupler (57) to swivel tee (61).

9.

Attach 4900 kPa (700 psi) pressure gauge (56) to coupler (57).

  • 10. Block the forward left travel by putting stopper (47) in position on the gear of sprocket (46).

  • 11. Attach a 49000 kPa (7100 psi) pressure gauge to each of taps (9) and (10).

  • 12. Run the engine at 1860 ± 50 rpm under no load. (Read rpm an elapse of three seconds after the engine

speed dial has been placed in position "10".)

Adjustment

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Sprocket (Left Track) (46) Sprocket. (47) Stopper. Preparation 1.

Main Control Valve Compartment (52) Connector (pilot on main control valves). (55) Pilot hose (travel line). (62) Elbow. (63) Pilot hose.

  • 1. Move the travel control lever to the FULL FORWARD position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

  • 2. Slowly move the stick control lever from the NEUTRAL position to the stick IN position.

  • 3. Hold the stick control lever at the position where the readings of the pressure gauges at taps (9) and

(10) have just begun to differ from each other.

  • 4. Loosen locknut (64) and turn screw (65) until the total pressure reading of the pressure gauges

connected to pilot hoses (55) and (63) is 4900 ± 200 kPa (700 ± 28 psi). Turning screw (65) clockwise,

increases the pressure. Turning screw (65) counterclockwise, decreases the pressure.

  • 5. Tighten locknut (64) to a torque of 160 ± 30 N·m (118 ± 22 lb ft).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Slowly move the stick control lever from the
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Slowly move the stick control lever from the

Swing Pump Compartment (1) Swing pump. (2) Tap (swing pump delivery pressure).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Slowly move the stick control lever from the

Front Swing Motor Compartment (3) Relief valve (left swing). (4) Front swing motor. (5) Relief valve (right swing). (6) Locknut. (7) Adjuster.

Preparation

  • 1. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

  • 2. Attach a 49 000 kPa (7100 psi) pressure gauge to tap (2) of swing pump (1).

  • 3. Start the engine and place the engine speed dial at position "10" with the power mode selector switch at

mode III position.

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

  • 5. Place the swing lock pin in the LOCKED position.

Adjustment Procedure

  • 1. Slowly move the swing control lever to the FULL RIGHT SWING position.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

  • 2. Loosen locknut (6) of relief valve (5) and turn adjuster (7) until the pressure gauge at tap (2) reads 27

500 ± 490 kPa (4000 ± 72 psi). Tighten locknut (6) to a torque of 155 ± 29 N·m (115 ± 22 lb ft).

Reference: Turning adjuster (7) clockwise increase the pressure. Turning adjuster (7) counterclockwise decreases the pressure.

  • 3. To adjust relief valve (3), slowly move the swing control lever to the FULL LEFT SWING position.

  • 4. Adjust relief valve (3) in the same manner as above Step 2.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Loosen locknut (6) of relief valve (5) and
5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Loosen locknut (6) of relief valve (5) and

Preparation

  • 1. Release the pressure in the hydraulic system. See the section, "Release Of Pressure In The Hydraulic

System".

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Loosen locknut (6) of relief valve (5) and

Main Pump Compartment (1) Tap (front pump).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 2. Loosen locknut (6) of relief valve (5) and

Pilot Oil Manifold Compartment (In Rear Of Main Control Valves) (2) Pilot oil manifold. (3) Tap.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Travel Motor (Left Track) (4) Signal pressure line. (5)

Travel Motor (Left Track) (4) Signal pressure line. (5) Coupler. (6) Swivel tee. (7) Connector.

  • 2. Install a 49 000 kPa (7100 psi) pressure gauge at tap (1) on the front pump.

  • 3. Install a 4900 kPa (700 psi) pressure gauge at tap (3) on the pilot oil manifold (2).

  • 4. Disconnect signal pressure line (4) from connector (7).

  • 5. Install swivel tee (6) between pressure line (4) and connector (7).

  • 6. Install coupler (5) to swivel tee (7).

  • 7. Attach a 4900 kPa (700psi) pressure gauge to coupler (5).

  • 8. Start the engine and place the power mode selector switch at Mode III position. Maintain a maximum

no load speed of 1860 ± 50 rpm with the AEC switch OFF.

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

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Travel Motor (Left Track) (4) Signal pressure line. (5)

Sprocket (Left Track) (8) Sprocket. (9) Stopper.

  • 10. Block the forward left travel by putting stopper (9) in position on the gear of sprocket (8).

  • 11. Place the travel speed control switch in the HIGH (rabbit sign) position.

  • 12. Check the pilot pressure on the gauge attached to tap (3). The pressure gauge should read 3450 kPa

(500 psi).

Adjustment

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Automatic Travel Speed Control Valve (In Rear Of Main

Automatic Travel Speed Control Valve (In Rear Of Main Control Valves) (10) Locknut. (11) Screw.

  • 1. While reading the pressure gauges connected to signal pressure line (4) and tap (1), slowly move the left

travel control lever to the FORWARD position. When system pressure at tap (1) reads 33 800 ± 490 kPa (4900 ± 72 psi), the pressure gauge connected to signal pressure line (4) should be reduced to 0 kPa (0 psi).

NOTE: This pressure is indicated when the automatic travel speed change valve causes the travel motor to shift to LOW speed.

  • 2. If the pressure gauge connected to signal pressure line (4) does not read 0 kPa (0 psi) at the same time

the gauge at system pressure at tap (1) reads 33 800 ± 490 kPa (4900 ± 72 psi), then adjust the automatic travel speed change valve as follows:

NOTE: Always make the final pressure adjustments during the pressure rise.

  • a. Loosen locknut (10) and turn screw (11) until the pressure gauge connected to signal pressure

line (4) reads 0 kPa (0 psi) when the pressure gauge at tap (1) reads 33 800 ± 490 kPa (4900 ± 72

psi).

NOTE: Turning screw (9) clockwise increases the pressure. Turning screw (9) counterclockwise decreases the pressure.

  • b. Tighten locknut (10) to a torque of 16 ± 1 N·m (12 ± 1 lb ft).

  • 3. Repeat Step 1.

  • 4. Move the left travel control lever to the FULL FORWARD position and then slowly return it to the

NEUTRAL position until the reading of pressure gauge connected to tap (1) decreases to 12 300 ± 490

kPa (1775 ± 72 psi).

  • 5. The pressure in the gauge connected to signal pressure line (4) reads 3450 kPa (500 psi).

NOTE: This pressure is indicated when the automatic travel speed change valve causes the travel motor to shift to HIGH speed.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Automatic Travel Speed Control Valve (In Rear Of Main

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Controller Compartment (1) Controller alarm lamp. (2) Controller. Right

Controller Compartment (1) Controller alarm lamp. (2) Controller.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Controller Compartment (1) Controller alarm lamp. (2) Controller. Right

Right Console (3) Monitor. (4) Monitor panel.

NOTE: Before starting pump flow tests, be sure the action alarm indicators on controller (2) and monitor panel (4) indicate Normal.

NOTE: If the operational tests (for example, cycle times) indicates that a slow implement problem is common to the circuits of one pump, then the problem is most likely in the hydraulic system. Then the "Pump Flow Test" should be made.

NOTE: If the operational tests indicate a implement speed problem common to both the pump circuits, then the engine fuel or working altitude may be the problem.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Controller Compartment (1) Controller alarm lamp. (2) Controller. Right

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 60

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 1 (Constant Horsepower

Illustration Of Flow Meter Tool Layout 1 (Constant Horsepower Control Test)(Main Pump) (1) Front pump. (2) Rear pump. (3) Sleeve. (4) Reusable coupling. (5) O-ring. (6) Coupler. (7) Nipple. (8) Adapter. (9) Adapter block. (10) Rectangular seal. (11) Bolt. (12) Hose. (13) Blocking plate. (14) Delivery hose (front pump). (15) Delivery hose (rear pump). (16) Flange. (17) Washer. (18) Bolt. (19) SAE reducing union. (20) O-ring. (21) Adapter. (22) Portable hydraulic tester. (23) Bolt. (25) Flange. (26) Return hose. (27) Adapter block. (28) O-ring. (29) Cover.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 1 (Constant Horsepower

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 2 (Constant Horsepower

Illustration Of Flow Meter Tool Layout 2 (Constant Horsepower Control Test)(Main Pump) (1) Front pump. (2) Rear pump. (31) Coupler. (32) Gauge. (33) Hose. (34) Nipple. (35) O-ring. (36) Plug. (37) Tee (front pump load sensing regulator). (38) Tee (Rear pump load sensing regulator). (39) Load signal hose (front pump). (40) Load signal hose (rear pump). (41) O-ring. (42) Swivel tee. (43) Cap.

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 2 (Constant Horsepower

To prevent personal injury or equipment damage from failure of the flow meter or associated circuit components because of blocked pump flow, make sure before starting the engine that the flow meter valve is fully open (turned counterclockwise).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 2 (Constant Horsepower

Preparation (Front Pump) (6XK1-114)

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Front

Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Front Pump) (1) Front pump. (2) Rear pump. (13) Plate. (14) Delivery hose. (16) Flange. (22) Portable hydraulic tester. (24) Block. (25) Flange. (26) Return hose. (29) Cover. (32) Pressure gauge. (33) Hose. (36) Plug. (37) Tee. (39) Load signal hose. (42) Swivel tee. (43) Cap. (44) Main control valves. (45) Tap (power shift pressure). (46) Pressure gauge. (47) Tap (front pump delivery pressure).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Front

Main Pump Compartment (1) Front pump. (2) Rear pump. (37) Tee. (39) Load signal hose. (45) Tap (power shift pressure). (47) Tap (front pump delivery pressure).

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Front

Main Control Valve Compartment (26) Return hose. (44) Main control valves.

5080 FRONT SHOVEL HYDRAULIC SYSTEM

SENR6167-01

____________________________________________________________________________________________________________________________

5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Flow Meter (22) Portable hydraulic tester (flow meter). (30)

Flow Meter (22) Portable hydraulic tester (flow meter). (30) Multitach. (48) Valve.

  • 1. Position the machine on level ground and stop the engine.

  • 2. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In

The Hydraulic System".

  • 3. Install the following tools in accordance with layout illustrations 1 and 2.

    • a. Disconnect delivery hose (14) from front pump (1).

    • b. Install plate (13) and flange (16) to the end of delivery hose (14).

    • c. Disconnect return hose (26) from block (24).

    • d. Install cover (29) and flange (25) to block (24).

    • e. Connect portable hydraulic tester (22) between front pump (1) and return hose (26).

    • f. Disconnect load signal hose (39) of main control valves (44) from load sensing regulator tee (37). Install plug (36) in the end of load signal hose (39).

    • g. Connect swivel tees (42) to tee (37). Install cap (43) on open end of swivel tee (42).

    • h. Connect hose (33) between front pump tap (47) and swivel tee (42).

    • i. Install pressure gauge (32) at swivel tee (42). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of 8T0861 pressure gauge.]

  • 4. Install 4900 kPa (700 psi) pressure gauge (46) at tap (45).

  • 5. Install multitach group (30) on to the engine. This is to read the engine speed rpm.

  • 6. Start the engine and place the power mode selector switch in Mode III position.

  • 7. Place the engine speed dial at position "10" and maintain the maximum no load speed at 1860 ± 50 rpm

  • with the AEC switch OFF. (Read the rpm three seconds elapsed time after the engine speed dial has been placed in position "10".

    • 8. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To do this, move the stick IN and OUT

    its full travel several times.

    Preparation (Front Pump) (8SL1-Up and 6XK115-Up)

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration of Tool Layout 3 (Front Pump Pressure Gauge

    Illustration of Tool Layout 3 (Front Pump Pressure Gauge Connection) (50) Coupler. (51) Hose. (52) Nipple. (53) Seal. (54) Seal. (55) Tee. (56) Plug. (57) Nipple. (58) Pressure Gauge. (59) Cap.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration of Tool Layout 3 (Front Pump Pressure Gauge

    Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Front Pump) (1) Front pump. (2) Rear pump. (13) Plate. (14) Delivery hose. (16) Flange. (22) Portable hydraulic tester. (24) Block. (25) Flange. (26) Return hose. (29) Cover. (32) Pressure gauge. (33) Hose. (37) Tee. (39) Load signal hose. (41) Load signal crossover hose. (42) Swivel tee. (43) Cap. (44) Main control valves. (45) Tap (power shift pressure). (46) Pressure gauge. (47)

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    Tap (front pump delivery pressure). (52) Nipple (Load sensing pressure tap).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Tap (front pump delivery pressure). (52) Nipple (Load sensing

    Main Pump Compartment (1) Front pump. (2) Rear pump. (39) Load signal hose. (45) Tap (power shift pressure). (47) Tap (front pump delivery pressure).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Tap (front pump delivery pressure). (52) Nipple (Load sensing

    Main Control Valve Compartment (Typical Example) (26) Return hose. (44) Main control valves.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Tap (front pump delivery pressure). (52) Nipple (Load sensing

    Flow Meter (22) Portable hydraulic tester (flow meter). (30) Multitach. (48) Valve.

    • 1. Position the machine on level ground and stop the engine.

    • 2. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In

    The Hydraulic System".

    • 3. Install the following tools in accordance with layout illustrations 1, 2 and 3.

      • a. Disconnect delivery hose (14) from front pump (1).

      • b. Install plate (13) and flange (16) to the end of delivery hose (14).

      • c. Disconnect return hose (26) from block (24).

      • d. Install cover (29) and flange (25) to block (24).

      • e. Connect portable hydraulic tester (22) between front pump (1) and return hose (26).

      • f. Disconnect load signal hose (39) from main control valves (44) from load sensing regulator tee (37). Install plug (56) in the end of load signal hose (39).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    • g. Connect swivel tees (42) to tee (37). Install cap (43) on open end of swivel tee (42).

    • h. Connect hose (33) between front pump tap (47) and swivel tee (42).

    • i. Install pressure gauge (32) at swivel tee (42). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of 8T0861 pressure gauge.]

    • 4. Install 4900 kPa (700 psi) pressure gauge (46) at tap (45).

    • 5. Install multitach group (30) on to the engine. This is to read the engine speed rpm.

    • 6. Start the engine and place the power mode selector switch in Mode III position.

    • 7. Place the engine speed dial at position "10" and maintain the maximum no load speed at 1860 ± 50 rpm

    with the AEC switch OFF. (Read the rpm three seconds elapsed time after the engine speed dial has been placed in position "10".

    • 8. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To do this, move the stick IN and OUT

    its full travel several times.

    Preparation (Rear Pump) (6XK1-114)

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ g. Connect swivel tees (42) to tee (37). Install

    Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Rear Pump) (2) Rear pump. (13) Plate. (15) Delivery hose. (16) Flange. (22) Portable hydraulic tester (flow meter). (26) Return hose. (32) Pressure gauge. (33) Hose. (36) Plug. (38) Tee. (40) Load signal hose. (42) Swivel tee. (43) Cap. (44) Main control valves. (46) Pressure gauge. (49) Tap (rear pump delivery pressure).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    Perform the same procedure as that described for the front pump flow test under constant horsepower control except Step 3. Use the following procedure in replacement for step 3 for the rear pump.

    • a. Disconnect delivery hose (15) from rear pump (2).

    • b. Install plate (13) and flange (16) to the end of delivery hose (15).

    • c. Disconnect return hose (26) from block (24).

    • d. Install cover (29) and flange (25) to block (24).

    • e. Connect portable hydraulic tester (flow meter) (22) between rear pump (2) and return hose (26).

    • f. Disconnect load signal hose (40) of main control valves (44) from load sensing regulator tee (38). Install plug (36) in the end of load signal hose (40).

    • g. Connect swivel tees (42) in series to tee (38). Install cap (43) on the open end in swivel tee (42).

    • h. Connect hose (33) between rear pump tap (49) and swivel tee (42).

    • i. Install pressure gauge (32) at swivel tee (42). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of 8T0861 pressure gauge.]

    Preparation (Rear Pump) (8SL1-Up and 6XK115-Up)

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Perform the same procedure as that described for the

    Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Rear Pump) (1) Front Pump. (2) Rear pump. (13) Plate. (15) Delivery hose. (16) Flange. (22) Portable hydraulic tester (flow meter). (24) Block. (25) Flange. (26) Return hose. (29) Cover. (32) Pressure gauge. (33) Hose. (38) Tee. (40) Crossover load sensing hose. (41) Load sensing hose from main control valve. (42) Swivel tee. (43) Cap. (44) Main control valves. (45) Tap. (46) Pressure gauge. (49) Tap (rear pump delivery pressure). (52) Load sensing tap.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration of Tool Layout 4 (Rear Pump Pressure Gauge

    Illustration of Tool Layout 4 (Rear Pump Pressure Gauge Connection) (50) Coupler. (51) Hose. (52) Nipple. (53) Seal. (54) Seal. (55) Tee. (57) Nipple. (58) Pressure Gauge. (59) Cap.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration of Tool Layout 4 (Rear Pump Pressure Gauge

    Illustration of Tool Layout 5 (Front Pump Pressure Gauge Connection) (54) Seal. (56) Plug.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump Compartment (2) Rear pump. (55) Tee. (45)

    Main Pump Compartment (2) Rear pump. (55) Tee. (45) Tap (power shift pressure) (49) Tap (rear pump delivery pressure).

    Preform the same procedure as that described for the "Front Pump Flow Test Under Constant Horsepower Control, Preparation (Front Pump)" except Step 3. Use the following procedure in replacement for Step 3 for the rear pump.

    • 3. Install the following tools in accordance with layout illustrations 1, 2, 4 and 5.

      • a. Disconnect delivery hose (15) from rear pump (2).

      • b. Install plate (13) and flange (16) to the end of delivery hose (15).

      • c. Disconnect return hose (26) from block (24).

      • d. Install cover (29) and flange (25) to block (24).

      • e. Connect portable hydraulic tester (flow meter) (22) between rear pump (2) and return hose (26).

      • f. Disconnect load sensing crossover hose (40) from rear pump and install plug (56).

      • g. Connect swivel tee (55) to tee (38). Install cap (43) on the open end in swivel tee (42). Install

    pressure gage to nipple (52).

    • h. Connect hose (51) between rear pump system pressure tap (49) and load sensing tap (52).

    • i. Install pressure gauge (32) at swivel tee (42). [A 49 000 kPa (7100 psi) pressure gauge can be used in place of 8T0861 pressure gauge.]

    Flow Test

    NOTE: Perform front and rear pump flow test one at time.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump Compartment (2) Rear pump. (55) Tee. (45)

    To prevent personal injury and/or equipment damage from failed lines or components while the flow meter is returned to the open flow position after a flow test, slowly open the flow meter valve and monitor pump flow at the same time to make sure flow increases. If pump flow does not increase as the flow meter is opened, shut the engine off and determine what is causing the pump not to upstroke.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Pump Compartment (2) Rear pump. (55) Tee. (45)
    • 1. With the engine running, start the service program "Calibration Mode" and maintain the power shift

    pressure at a constant pressure of 1500 ± 50 kPa (220 ± 7 psi). The power shift pressure is read at tap (45)

    using pressure gauge (46).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    NOTE: During the test, never try to turn the starter switch OFF to prevent any change in power shift pressure.

    • 2. Slowly turn valve (48) of portable hydraulic tester (22) clockwise and record pump flow at each of

    following pressure points. Use pressure gauge (32) for this pressure reading.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: During the test, never try to turn the

    P-Q Characteristic Curve [At 1500 kPa (220 psi) Power Shift Pressure]

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: During the test, never try to turn the

    NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To get more accurate test results, each of measurements should be corrected by calculating as follows.

    Flow corrected = (Flow measured x 1800) ÷ RPM measured

    • 3. Any flow readings must be done only in upstroke.

    • 4. The pump flow changes approximately 30 liter/min. (7.9 U.S. gpm) for each 100 kPa (14 psi) of power

    shift pressure.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: During the test, never try to turn the

    To prevent damages to the main pump and associated circuit components because of too high pump delivery pressure, make sure to reconnect each of load signal hoses (39) and (40) to its original pump

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    regulator after completion of the main pump flow test.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ regulator after completion of the main pump flow test.
    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ regulator after completion of the main pump flow test.

    If flow measurements are out of specifications, adjust the flow as follows.

    NOTE: Any flow variation per one turn of a setscrew should be used as a guide only. Always use a flow meter to adjust the pump flow.

    Main Pumps

    NOTE: Main pump flow adjustment procedure for each of the front and rear pumps is the same. Description is given to the front pump as a typical example.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ regulator after completion of the main pump flow test.

    Front Pump (1) Locknut. (2) Setscrew. (3) Setscrew. (4) Locknut.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    Flow Adjustment Under Constant Horsepower Control

    • 1. Loosen locknut (4).

    • 2. Turn setscrew (3) until adjusted to the correct specification. Turning setscrew (3) clockwise decreases

    flow rate. Turning setscrew (3) counterclockwise increases flow rate. One turn of setscrew (3) changes flow rate approximately 50 liter/min (13 U.S. gpm) at a system pressure of 25 500 kPa (3700 psi).

    • 3. Tighten locknut (4) to a torque of 12 ± 3 N·m (9 ± 3 lb ft).

    Maximum Flow Adjustment

    • 1. Loosen locknut (1).

    • 2. Turn setscrew (2) until adjusted to the correct specification. Turning setscrew (2) clockwise decreases

    flow rate. Turning setscrew (2) counterclockwise increases flow rate. One turn of setscrew (3) changes

    flow rate approximately 34 liter/min. (9.0 U.S. gpm).

    • 3. Tighten locknut (1) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Flow Adjustment Under Constant Horsepower Control 1. Loosen locknut

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 74

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 3 (Constant Horsepower

    Illustration Of Flow Meter Tool Layout 3 (Constant Horsepower Control Test) (Swing Pump) (1) Swing pump. (2) Hose. (3) Sleeve. (4) Reusable coupling. (5) O-ring. (6) Coupler. (7) Nipple. (8) Adapter. (9) Adapter block. (10) Rectangular seal. (11) Bolt. (12) Cover. (13) Blocking plate. (14) Delivery hose (swing pump). (15) Block. (16) Flange. (17) Washer. (18) Bolt. (19) SAE reducing union. (20) O-ring. (21) Adapter. (22) Portable hydraulic tester. (23) Bolt. (24) Washer. (25) Flange. (26) Return hose. (27) Adapter. (28) O-ring.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 76

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 4 (Constant Horsepower

    Illustration Of Flow Meter Tool Layout 4 (Constant Horsepower Control Test)(Swing Pump) (30) Pilot hose (swing power control). (31) Pilot hose (positive flow control). (32) Seal. (33) Plug. (34) Seal. (35) Nipple. (36) Coupler. (37) Hose. (38) Block (pilot pump). (39) Connector. (40) Swivel tee. (41) Cap.

    Preparation

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Swing

    Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Swing Pump) (1) Swing pump. (12) Cover. (13) Plate. (14) Delivery hose. (15) Block. (16) Flange. (22) Portable hydraulic tester (flow meter). (25) Flange. (26) Return hose. (30) Pilot hose (swing power control). (31) Pilot hose (positive flow control). (33) Plug. (37) Hose. (38) Block (pilot pump). (40) Swivel tee. (41) Cap. (42) Pressure gauge. (43) Pressure gauge. (44) Swing control valve. (45) Pilot oil manifold. (46) Pilot pump. (47) Regulator.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Under Constant Horsepower Control)(Swing

    Swing Pump Compartment (1) Swing pump. (38) Block. (46) Pilot pump. (48) Tap (pilot pump delivery pressure). (49) Tap (swing pump delivery pressure).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valve Compartment (26) Return hose. (50) Main

    Main Control Valve Compartment (26) Return hose. (50) Main control valves.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valve Compartment (26) Return hose. (50) Main

    Pilot Oil Manifold Compartment (In Rear Of Main Control Valves) (45) Pilot oil manifold. (51) Tap (pilot pump delivery pressure).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valve Compartment (26) Return hose. (50) Main

    Flow Meter (22) Portable hydraulic tester (flow meter). (29) Multitach. (52) Valve.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valve Compartment (26) Return hose. (50) Main

    To prevent personal injury or equipment damage from failure of the flow meter or associated circuit components because of blocked pump flow, make sure before starting the engine that the flow meter valve is fully open (turned counterclockwise).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Main Control Valve Compartment (26) Return hose. (50) Main
    • 1. Position the machine on level ground and stop the engine.

    • 2. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In

    The Hydraulic System".

    • 3. Install necessary tools in accordance with the layout Illustrations 3 and 4 as follows:

      • a. Disconnect delivery hose (14) from swing pump (1).

      • b. Install plate (13) and flange (16) to the end of delivery hose (14).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    • c. Disconnect return hose (26) from block (15).

    • d. Install cover (12) and flange (25) to block (15).

    • e. Connect portable hydraulic tester (flow meter) (22) between swing pump (1) and return hose

    (26).

    • f. Disconnect pilot hoses (30) and (31) from swing pump regulator (47). Install plug (33) in the open end of each of pilot hoses (30) and (31).

    • g. Remove tap (48) from block (38) of pilot pump (46).

    • h. Connect swivel tees (40) to the port of block (38) where tap (48) was removed. Install cap (41) to

    open end of swivel tee (40).

    • i. Connect hose (37) between swivel tee (40) and the open port of regulator (47) where pilot hose (30) was removed.

    • j. Connect the other hose (37) between swivel tee (40) and the open port of regulator (47) where

    pilot hose (31) was removed.

    • 4. Install pressure gauge (42) at tap (49). A 49 000 kPa (7100psi) pressure gauge can be used in place of a

    8T0861 pressure gauge.

    • 5. Install 4900 kPa (700 psi) pressure gauge (43) to tap (51) of pilot oil manifold (45).

    • 6. Install multitach (29) on the engine. This is to read engine speed rpm.

    • 7. Start the engine and place the power mode selector switch in Mode III position.

    • 8. Place the engine speed dial at position "10" and run the engine at no load speed of 1860 ± 50 rpm with

    AEC switch OFF. (Read rpm after a elapse of 3 seconds after the speed dial has been placed in position

    "10".)

    • 9. Place the swing lock pin in the LOCKED position.

      • 10. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To do this, move the stick IN and OUT

    its full travel several times.

    • 11. Pressure gauge (43) at tap (51) should read 3450 + 100 -0 kPa (500 + 14 -0 psi).

    Flow Test

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ c. Disconnect return hose (26) from block (15). d.

    To prevent personal injury and/or equipment damage from failed lines or components while the flow meter is returned to the open flow position after a flow test, slowly open the flow meter valve and monitor pump flow at the same time to make sure flow increases. If pump flow does not increase as the flow meter is opened, shut the engine off and determine what is causing the pump not to upstroke.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ c. Disconnect return hose (26) from block (15). d.
    • 1. Slowly turn valve (52) of portable hydraulic tester (flow meter) (22) clockwise and record pump flow at

    each of the following pressure points. Use pressure gauge (42) for this pressure reading.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ P-Q Characteristic Curve NOTE: Flow specifications given above are

    P-Q Characteristic Curve

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ P-Q Characteristic Curve NOTE: Flow specifications given above are

    NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To get more accurate test results, each of measurements should be corrected by calculating as follows.

    Flow corrected = (Flow measured × 1800) ÷ rpm measured

    • 2. Any flow readings must be done only in upstroke.

    • 3. During this test, check to be sure that the high pressure cut characteristic correctly functions. This can

    be done by identifying a sudden flow decrease when the delivery pressure reaches close to 27 500 kPa

    (4000 psi).

    • 4. Under the above test condition, the swing pump runs at a speed of 1913 rpm.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ P-Q Characteristic Curve NOTE: Flow specifications given above are

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ 82

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 3 (Positive Flow

    Illustration Of Flow Meter Tool Layout 3 (Positive Flow Control Test)(Swing Pump) (1) Swing pump. (2) Hose. (3) Sleeve. (4) Reusable coupling. (5) O-ring. (6) Coupler. (7) Nipple. (8) Adapter. (9) Adapter block. (10) Rectangular seal. (11) Bolt. (12) Cover. (13) Blocking plate. (14) Delivery hose (swing pump). (15) Block. (16) Flange. (17) Washer. (18) Bolt. (19) SAE reducing union. (20) O-ring. (21) Adapter. (22) Portable hydraulic tester. (23) Bolt. (24) Washer. (25) Flange. (26) Return hose. (27) Adapter. (28) O-ring.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 5 (Positive Flow
    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Illustration Of Flow Meter Tool Layout 5 (Positive Flow

    Illustration Of Flow Meter Tool Layout 5 (Positive Flow Control Test)(Swing Pump) (30) Pilot hose (swing power control). (31) Pilot hose (positive flow control). (32) Seal. (33) Plug. (34) Seal. (35) Nipple. (36) Coupler. (37) Hose. (39) Swivel tee. (40) Pressure gauge. (43) Regulator. (42) Tap (pilot pump delivery pressure).

    Preparation

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Positive Flow Control Test)(Swing

    Circuit Diagram For Flow Test (Positive Flow Control Test)(Swing Pump) (1) Swing pump. (12) Cover. (13) Plate. (14) Delivery hose. (15) Block. (16) Flange. (22) Portable hydraulic tester (flow meter). (25) Flange. (26) Return hose. (30) Pilot hose (swing power control). (31) Pilot hose (positive flow control). (33) Plug. (37) Hose. (40) Pressure gauge. (41) Pressure gauge. (42) Tap (pilot pump delivery pressure). (43) Regulator. (44) Swing control valve. (45) Pilot oil manifold. (46) Pilot pump.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Positive Flow Control Test)(Swing

    Swing Pump Compartment (1) Swing pump. (38) Block. (46) Pilot pump. (48) Tap (pilot pump delivery pressure). (49) Tap (swing pump delivery pressure).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Circuit Diagram For Flow Test (Positive Flow Control Test)(Swing

    Main Control Valve Compartment (26) Return hose. (38) Main control valves.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pilot Oil Manifold Compartment (In Rear Of Main Control

    Pilot Oil Manifold Compartment (In Rear Of Main Control Valves) (45) Pilot oil manifold. (47) Tap (pilot pump delivery pressure).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pilot Oil Manifold Compartment (In Rear Of Main Control

    Flow Meter (22) Portable hydraulic tester (flow meter). (29) Multitach. (48) Valve.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pilot Oil Manifold Compartment (In Rear Of Main Control

    To prevent personal injury or equipment damage from failure of the flow meter or associated circuit components because of blocked pump flow, make sure before starting the engine that the flow meter valve is fully open (turned counterclockwise).

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Pilot Oil Manifold Compartment (In Rear Of Main Control
    • 1. Position the machine on level ground and stop the engine.

    • 2. Release the pressure in the hydraulic system. See the section in this module, "Release Of Pressure In

    The Hydraulic System".

    • 3. Install necessary tools in accordance with the layout illustrations 3 and 5 as follows:

      • a. Disconnect delivery hose (14) from swing pump (1).

      • b. Install plate (13) and flange (16) to the end of delivery hose (14).

      • c. Disconnect return hose (26) from block (15).

      • d. Install cover (12) and flange (25) to block (15).

      • e. Connect portable hydraulic tester (22) between swing pump (1) and return hose (26).

      • f. Disconnect pilot hose (30) from swing pump regulator (43). Install plug (33) in the end of pilot hose (30).

      • g. Connect hose (37) between tap (42) and the open port of regulator (43) where pilot hose (30) was

    removed.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    h. Disconnect pilot hose (31) from regulator (43). Connect pressure gauge (40) between pilot hose (31) and the open port of regulator (43). A 4900 kPa (700 psi) pressure gauge can be used in place of a 8T0855 pressure gauge.

    • 4. Install pressure gauge (41) at tap (42). A 4900 kPa (700 psi) pressure gauge can be used in place of a

    8T0861 pressure gauge.

    • 5. Install 4900 kPa (700 psi) pressure gauge (40) at tap (47) on pilot oil manifold (45).

    • 6. Install multitach (29) on the engine. This is to read engine speed rpm.

    • 7. Start the engine and place the power mode selector switch in Mode III position.

    • 8. Place the engine speed dial at position "10" and run the engine at no load speed of 1860 ± 50 rpm with

    AEC switch OFF. (Read rpm after a elapse of 3 seconds after the speed dial has been placed in position

    "10".)

    • 9. Place the swing lock pin in the LOCKED position.

      • 10. Increase the hydraulic oil temperature to 55 ± 5°C (131 ± 9°F). To do this, move the stick IN and OUT

    its full travel several times.

    • 11. Pressure gauge (40) at tap (47) should read 3450 + 100 -0 kPa (500 +14 -0 psi).

    Flow Test

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ h. Disconnect pilot hose (31) from regulator (43). Connect

    To prevent personal injury and/or equipment damage from failed lines or components while the flow meter is returned to the open flow position after a flow test, slowly open the flow meter valve and monitor pump flow at the same time to make sure flow increases. If pump flow does not increase as the flow meter is opened, shut the engine off and determine what is causing the pump not to upstroke.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ h. Disconnect pilot hose (31) from regulator (43). Connect
    • 1. Slowly turn valve (48) of portable hydraulic tester (flow meter) (22) clockwise until the swing pump

    delivery pressure is 6850 kPa (1000 psi). Read pressure gauge (41) at tap (42).

    • 2. Gradually move the swing control lever to RIGHT SWING position until pressure gauge (40) between

    pilot hose (31) and the port of regulator (43) reads 1370 kPa (200 psi) and hold the control lever at this position. Then record the swing pump flow under positive flow control.

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: Flow specifications given above are based on an

    NOTE: Flow specifications given above are based on an engine speed of 1800 rpm. To get more accurate test results, measured flow should be corrected by calculating as follows:

    Flow corrected = (Flow measured × 1800) ÷ rpm measured

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ NOTE: Flow specifications given above are based on an

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    5080 FRONT SHOVEL HYDRAULIC SYSTEM SENR6167-01 ____________________________________________________________________________________________________________________________ Swing Pump (1) Setscrew. (2) Locknut. (3) Locknut. (4)

    Swing Pump (1) Setscrew. (2) Locknut. (3) Locknut. (4) Setscrew. (5) Locknut. (6) Setscrew.

    Constant Horsepower Flow Adjustment

    • 1. Loosen locknut (5).

    • 2. Turn setscrew (6) until adjusted to the correct specification. Turning setscrew (6) clockwise increases

    flow rate. Turning setscrew (6) counterclockwise decreases flow rate. One turn of setscrew (6) changes flow rate approximately 65 liter/min. (17 U.S. gpm) at a system pressure of 19 600 kPa (2850 psi).

    • 3. Tighten locknut (5) to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

    Maximum Flow Adjustment

    • 1. Loosen locknut (3).

    • 2. Turn setscrew (4) until adjusted to the correct specification. Turning setscrew (4) clockwise decreases

    5080 FRONT SHOVEL HYDRAULIC SYSTEM

    SENR6167-01

    ____________________________________________________________________________________________________________________________

    flow rate. Turning setscrew (4) counterclockwise increases flow rate. One turn of setscrew (4) changes flow rate approximately 30 liter/min. (7.9 U.S. gpm).

    • 3. Tighten locknut (3) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

    Flow Adjustment Under Positive Flow Control

    • 1. Loosen locknut (2).

    • 2. Turn setscrew (1) until adjusted to the correct specification. Turning setscrew (1) clockwise increases

    flow rate. Turning setscrew (1) counterclockwise decreases flow rate. A half turn of setscrew (1) changes flow rate approximately 90 liter/min. (24 U.S. gpm).

    • 3. Tighten locknut (1) to a torque of 27 ± 7 N·m (20 ± 5 lb ft).

    NOTE: Pressure variation per one turn of a setscrew should be used as a guide only. Always use a pressure gauge to make pressure adjustment.

    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua

    Technical Library

    http://engine.od.ua

    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua
    Technical Library http://engine.od.ua