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SENR6167-01

Testing and
Adjusting
5080 FRONT SHOVEL HYDRAULIC SYSTEM
S/N 6XK1-UP

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5080 FRONT SHOVEL HYDRAULIC SYSTEM


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Testing and Adjusting


5080 FRONT SHOVEL HYDRAULIC SYSTEM
Media Number -SENR6167-01

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.

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

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
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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.

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.

(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".

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(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)

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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

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.

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.
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(Hyd #5)
Pilot Oil Pressure Check At Swing Control Valve Inlet

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.

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.
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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.

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)

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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.

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.

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

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 m3 (6-3/4 yd3) bucket.
NOTE: The power mode selector switch must be placed at Mode III position, unless otherwise specified,
during tests.

Conditions for the following tests are as follows:


1. Engine speed: No load high idle, 1860 50 rpm
2. Hydraulic oil temperature: 55 5C (130
NOTE: Fully move the stick in and out several times until the normal hydraulic oil temperature is
reached.
3. Delivery pressure settings:
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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)

Test Preparation:

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:
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1. Start the engine and place the power mode selector switch in Mode III position. Place the engine speed
dial at position "10" and the travel speed switch in HIGH (rabbit) position. Move the machine by
operating both travel levers at the same time.
2. The first 5 m (16.5 ft) are for a preliminary run. Measure the time required for the machine to travel the
remaining 20 m (66 ft) in each direction (FORWARD and REVERSE).
3. Measure the 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:

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

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:

Test Preparation:
1. Place the machine on level ground.

Test Procedure:

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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.

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:

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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:

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.

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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.

2. Put marks on both inner and outer races of the swing bearing to indicate relation of two positions.

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.
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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.

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.

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.

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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.

2. Measure the time needed to swing the upper structure 90 counterclockwise up hill. Do the same for a
90 turn clockwise up hill.

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.
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2. Put marks on inner and outer races of the swing bearing.

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.

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Test Preparation:

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):

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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.

Test Preparation:
1. Place the machine on level ground.
2. The bucket must be empty.

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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.

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.

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

Test Procedure (Bucket Cylinder)


1. Position the upper surface of the boom parallel and the stick perpendicular to the ground.
Extension Test;
Measure the time required for the bucket cylinder to reach full extension position from full retraction
position.

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

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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.

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)

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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) Front
pump. (10) Pilot oil manifold. (11) Travel motor (left).

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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)

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.

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(8SL1-Up and 6XK1-Up)

Pressure Variation By Adjusting Screw (6XK1-114)

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

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

Preparation

Pilot Oil Manifold Compartment


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

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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 5C (131 9F).
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.

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.

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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.

1. Disable sequence valve (7).


Reference: Make reference to "Disabling Sequence Valve".

Preparation

Front Of Main Control Valves


(6) Pilot hose. (7) Sequence valve.

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
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(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

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.

Preparation
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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.

Main Pump Compartment


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

Main Control Valve Compartment


(8) Boom raise pilot line.

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Illustration of Tool Layout 1 (Boom Raise Pilot Line)


(20) Pressure gauge. (21) Nipple. (22) Coupler. (23) Hose. (24) Nipple. (25) Seal. (26) Seal.

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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.

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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

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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.

Preparation (6XK1-114)
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Main Control Valves


(21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief valve
(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).

Signal Relief Valve (Boom Circuit)


(29) Signal relief valve (boom circuit). (31) Locknut. (32) Screw.

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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.

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.

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
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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)

Main Control Valves


(21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief valve
(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).

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Signal Relief Valve (Boom, Stick, Bucket, Bottom Dump Circuits)


(24) Signal relief valve (boom circuit). (33) Locknut. (34) Screw.

Signal Relief Valve (Travel Circuits)


(25) Signal relief valve (travel). (31) Locknut. (32) Screw.

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".
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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)

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

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).
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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)

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).

Crossover Relief Valve


(40) Adjuster. (41) Locknut. (43) Locknut. (44) Adjuster.

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Sprocket (Left Track)


(46) Sprocket. (47) Stopper.

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.
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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".

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.

Main Control Valves


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(21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief valve
(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).

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;

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).

Main Pump Compartment


(8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).
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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).

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).

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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).

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.

Main Control Valves


(21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief valve
(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;

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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).

Main Pump Compartment (Typical Example)


(8) Tap (rear pump delivery pressure). (9) Tap (front pump delivery pressure).

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).

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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).

Main Pump Compartment


(48) Differential relief valve (front pump). (49) Differential relief valve (rear pump).

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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.

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Main Control Valves


(21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief valve
(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).

Main Pump Compartment (Typical Example)


(48) Differential relief valve (front pump). (49) Differential relief valve (rear pump).
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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.

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Main Control Valves


(21) Line relief valve (bottom dump cylinder head end). (22) Line relief valve (bucket cylinder head end). (23) Line relief valve
(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).

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

Adjustment Procedure Option 1

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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).

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Main Control Valve Compartment


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

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

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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 Nm (118 22 lb ft).

Adjustment Procedure Option 2

Main Control Valve Compartment


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

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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

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.

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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 Nm (118 22 lb ft).

Swing Pump Compartment


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

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 5C (131 9F).
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.

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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 Nm (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.

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

Main Pump Compartment


(1) Tap (front pump).

Pilot Oil Manifold Compartment (In Rear Of Main Control Valves)


(2) Pilot oil manifold. (3) Tap.

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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 5C (131 9F).

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

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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 Nm (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.

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

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.

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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.

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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.

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).

Preparation (Front Pump) (6XK1-114)

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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).

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).

Main Control Valve Compartment


(26) Return hose. (44) Main control valves.
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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 5C (131 9F). To do this, move the stick IN and OUT
its full travel several times.

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

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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.

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

Main Pump Compartment


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

Main Control Valve Compartment (Typical Example)


(26) Return hose. (44) Main control valves.

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).
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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 5C (131 9F). To do this, move the stick IN and OUT
its full travel several times.

Preparation (Rear Pump) (6XK1-114)

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).

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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)

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.

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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.

Illustration of Tool Layout 5 (Front Pump Pressure Gauge Connection)


(54) Seal. (56) Plug.

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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.

To prevent personal injury and/or equipment damage from failed lines


or components while the flow meter is returned to the open flow position
after a flow test, slowly open the flow meter valve and monitor pump
flow at the same time to make sure flow increases. If pump flow does not
increase as the flow meter is opened, shut the engine off and determine
what is causing the pump not to upstroke.
1. With the engine running, start the service program "Calibration Mode" and maintain the power shift
pressure at a constant pressure of 1500 50 kPa (220 7 psi). The power shift pressure is read at tap (45)
using pressure gauge (46).
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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.

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

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.

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
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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.

Front Pump
(1) Locknut. (2) Setscrew. (3) Setscrew. (4) Locknut.
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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 Nm (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 Nm (74 15 lb ft).

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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.

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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

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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.

Swing Pump Compartment


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

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Main Control Valve Compartment


(26) Return hose. (50) Main control valves.

Pilot Oil Manifold Compartment (In Rear Of Main Control Valves)


(45) Pilot oil manifold. (51) Tap (pilot pump delivery pressure).

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

To prevent personal injury or equipment damage from failure of the


flow meter or associated circuit components because of blocked pump
flow, make sure before starting the engine that the flow meter valve is
fully open (turned counterclockwise).
1. Position the machine on level ground and stop the engine.
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).

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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 5C (131 9F). 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

To prevent personal injury and/or equipment damage from failed lines


or components while the flow meter is returned to the open flow position
after a flow test, slowly open the flow meter valve and monitor pump
flow at the same time to make sure flow increases. If pump flow does not
increase as the flow meter is opened, shut the engine off and determine
what is causing the pump not to upstroke.
1. 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.
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P-Q Characteristic Curve

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

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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.

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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

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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.

Swing Pump Compartment


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

Main Control Valve Compartment


(26) Return hose. (38) Main control valves.

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Pilot Oil Manifold Compartment (In Rear Of Main Control Valves)


(45) Pilot oil manifold. (47) Tap (pilot pump delivery pressure).

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

To prevent personal injury or equipment damage from failure of the


flow meter or associated circuit components because of blocked pump
flow, make sure before starting the engine that the flow meter valve is
fully open (turned counterclockwise).
1. Position the machine on level ground and stop the engine.
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.

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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 5C (131 9F). 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

To prevent personal injury and/or equipment damage from failed lines


or components while the flow meter is returned to the open flow position
after a flow test, slowly open the flow meter valve and monitor pump
flow at the same time to make sure flow increases. If pump flow does not
increase as the flow meter is opened, shut the engine off and determine
what is causing the pump not to upstroke.
1. 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.

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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

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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 Nm (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
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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 Nm (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 Nm (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.

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