8001

Section
8001

SPECIFICATIONS, TROUBLESHOOTING,
INSPECTIONS AND HYDRAULIC PRESSURE SETTING

Copyright @ 2008 CNH America LLC.

All rights reserved.
Printed in USA.
CNH Lep SM470B8001-0NA July 2008
8001-2
TABLE OF CONTENTS

WARNING: This symbol is used in this manual to indicate important safety messages. Whenever you see
! this symbol, carefully read the message which follows. Your safety depends on it.

SPECIFICATIONS .................................................................................................................................................... 5

SPECIAL TOOLS ...................................................................................................................................................... 5

Tester .................................................................................................................................................................... 5

HYDRAULIC EQUIPMENT LAYOUT........................................................................................................................ 7

Overall view .......................................................................................................................................................... 7
Pump chamber...................................................................................................................................................... 8
Swing body center section .................................................................................................................................... 9
Housing left side ................................................................................................................................................. 10
Cab ..................................................................................................................................................................... 11

IDENTIFICATION OF HYDRAULIC COMPONENTS ............................................................................................. 12

Pump................................................................................................................................................................... 12
Control valve ....................................................................................................................................................... 13
5 Way solenoid valve .......................................................................................................................................... 15
2 Way solenoid valve .......................................................................................................................................... 16
Remote control valves (upper side, travel).......................................................................................................... 17
Cushion valve ..................................................................................................................................................... 18
Safety valve (Option for Europe)......................................................................................................................... 19
Manifolds............................................................................................................................................................. 21
Swing motor ........................................................................................................................................................ 23
Travel motor ........................................................................................................................................................ 24
Center joint.......................................................................................................................................................... 25

PREPARATION BEFORE INSPECTION................................................................................................................ 26

Releasing pressure in the hydraulic system and Pressure measurement preparations ..................................... 26
Procedures for pressure measurement from the monitor display ....................................................................... 27
Procedures for measuring hydraulic oil temperature from the monitor display ................................................... 28
Pressure measuring port..................................................................................................................................... 29
Control valve ....................................................................................................................................................... 30
Location of relief valves ...................................................................................................................................... 30

PRESSURE MEASUREMENT................................................................................................................................ 31
Main Pressure Measurement .............................................................................................................................. 31
Pilot pressure measurement ............................................................................................................................... 35
Negative pressure measurement ........................................................................................................................ 36

PRESSURE ADJUSTMENT ................................................................................................................................... 37

Main pressure adjustment................................................................................................................................... 37
Pilot pressure adjustment ................................................................................................................................... 40

HYDRAULIC PUMP FLOW MEASUREMENT PROCEDURE ................................................................................ 41

Work preparations............................................................................................................................................... 41
Flow measurement ............................................................................................................................................. 44
Flow curve........................................................................................................................................................... 45

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 8001-3
DRAIN VOLUME MEASUREMENT PROCEDURE................................................................................................ 46
Preparations ....................................................................................................................................................... 46
Travel motor drain volume measurement ........................................................................................................... 46
Swing motor drain volume measurement ........................................................................................................... 48

AIR BLEED PROCEDURE ..................................................................................................................................... 49

Hydraulic pump................................................................................................................................................... 49
Travel motor........................................................................................................................................................ 50
Swing motor........................................................................................................................................................ 51
Safety valve ........................................................................................................................................................ 52

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8001-4
NOTES:
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 8001-5
SPECIFICATIONS
See section 1002.

SPECIAL TOOLS
Tester

1 2
3

CS02K573 CD01B005
1. OEM 1652 DIGITAL PRESSURE GAUGE 3. FEMALE COUPLING JOINT E47894 (1)
PRESSURE TEST POINT 14X1.5 A3237549 (2)
MALE COUPLING JOINT WITH UNION (3) AND
PLUGS (4) CONTAINED IN THE SUITCASE CAS
40023A.

CS02K574
2. OEM 1653 DIGITAL PRESSURE TEMPERATURE
ANALYSER
CS99B532
4. SET OF UNIONS FOR PRESSURE TEST AND
HYDRAULIC FLOW CAS 40023A AND CAS
40035.

Lep SM470B8001-0NA Issued 07-08

8001-6

CD99C002
5. SET OF HIGH PRESSURE HYDRAULIC HOSES
CAS 30036 (INCLUDING TWO HIGH PRESSURE
HOSES).

B785789R
6. CAS 10280 FLOW METER

Lep SM470B8001-0NA Issued 07-08

 8001-7
HYDRAULIC EQUIPMENT LAYOUT
Overall view

1
3

TD01013-001

1 Left side housing

2 Swing body center section
3 Pump compartment
4 Hydraulic oil tank
5 Fuel tank

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8001-8
Pump chamber

3 5

5 1

6 8

4 7 TD01013-501

1 Hydraulic pump 6 Pilot pump

2 Accumulator 7 N2 pressure sensor
3 Pilot filter 8 Horsepower control electromagnetic proportional valve
4 5 stack solenoid valve 9 Hydraulic oil temperature sensor
5 N1 pressure sensor

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 8001-9
Swing body center section

2 1 3
1

3
4 5

TD01013-502

1 Swing motor 4 P2 pressure sensor

2 Center joint 5 P1 pressure sensor
3 Control valve

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8001-10
Housing left side

2 1

TD01013-503

1 Cushion valve (with heat circuit) 4 Oil cooler

2 Swing pilot pressure sensor 5 Hydraulic motor fan
3 Selector valve installation seating

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 8001-11
Cab

1 2

RST 04 01 00

1 Travel remote control valve

2 Upper operation remote control valve

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8001-12
IDENTIFICATION OF HYDRAULIC COMPONENTS
Pump
(Dr)
Dr3
a3
B4 A3 Pi1 P1

B3

Pi1

a5 B4

Dr

P1

A4
Dr Psv Pi2
a1
a4 A-
A
Pi1
a5 P1 Pi2
Pi2

a4
a4
Dr Psv Psv
A3
a3
B1 (Dr)
B1 Dr3

B3

a1 a2 a2

a1 a2
A1 A2

TD06014-001

Port Description Port size

A1, A2 Discharge port SAE6000psi 1
B1 Suction port SAE2000psi 3
Dr Drain port G3/4-23
Pi1 Pilot port G 1/4-13
Pi2 Pilot port G 1/4-15
P1 Proportional valve primary pressure port G 1/4-13
Psv Servo assist port G 1/4-15
PB Boost pressure detection port Rc 1/8-12
a1, a2, a5, a5 Gauge port G 1/4-15
a3 Gauge port G 1/4-14
A3 Gear pump delivery port G 1/2-19
B3 Gear pump suction port G 3/4-20.5
Dr3 Gear pump drain port G3/8-15
A4 Gear pump delivery port SAE 5000psi 1
B4 Gear pump suction port SAE 4000psi 1 1/4
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 8001-13
Control valve

B-

1 6 11 15

2 7 12 16

3 8 13 17

4 9 14 18

5 10

B
A-
TD06014-002

1 Arm 1 out 10 Left travel backward

2 Option 11 Arm 2 in
3 Boom 2 down 12 Bucket close
4 Swing left 13 Boom 1 up
5 Left travel forward 14 Right travel backward
6 Arm 1 in 15 Arm 2 out
7 Option 16 Bucket open
8 Boom 2 up 17 Boom 1 down
9 Swing right 18 Right travel forward

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8001-14

Port Description Port Description

B8 Bucket-open line ps1, ps2 Negative control signal
A8 Bucket-close line PT Travel signal pressure measurement
B7 Boom-down line PA Upper signal pressure measurement
A7 Boom-up line pr1, pr2 Main pressure measurement
B6 Right travel forward line PH Pressure boost
A6 Right travel backward line PP Pilot pressure
B5 Arm-out line DR1', DR2' Drain
A5 Arm-in line T3 Swing motor; Make-up
A2 Right swing line T5 Bypass filter
B2 Left swing line T6 Heat circuit
A4 Option line pc1 Arm load holding
B4 Option line pc2 Boom load holding
B1 Left travel forward line pc4 Swing priority (for arm operation)
A1 Left travel backward line pc5 Boom-up priority
P1, P2 Pressure line pa10 Option merge
T1, T2 Return line

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 8001-15
5 Way solenoid valve

C2

C3

C1

B
T
RST-04-06-001f01 RST-04-06-001f02

3
C5
C4 4
1

P 5
2

RST-04-06-001f03 RST-04-06-001f04

1 Power save/removal and installation of counterweight

2 Lever lock
3 Swing lock
4 Pressure boost
5 Travel high speed

Port Location
C2 G1/4
C3 G1/4
C1 G1/4
C5 G1/4
C4 G1/4
P G3/8
B G3/8
T G3/8

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8001-16
2 Way solenoid valve

B1
A2

B2 A1
T
ND06008-020 ND06008-021

Port Location
A1 G1/4
B1 G1/4
A2 G1/4
B2 G1/4
T G1/4

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 8001-17
Remote control valves (upper side, travel)
1. Remote control valve (left, right)

Right side Left side

4
2 T
2
P
T 4
3 P
1 1
P 3
4 T
1 2
3 3
P 1
4 T 2
RST-04-06-001g01 RST-04-06-001g02

Port Right side Left side Location

1 Bucket close Swing right G3/8
2 Boom-down Arm-in G3/8
3 Bucket open Swing left G3/8
4 Boom-up Arm-out G3/8
P Pressure Pressure G1/4
T Return Return G3/8

2. Remote control valve (Travel)

1 3

2 4 RST-04-06-001m

Port Description Location

1 Backward left G1/4
2 Forward left G1/4
3 Backward right G1/4
4 Forward right G1/4
P Pressure G1/4
T Return G1/4

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8001-18
Cushion valve

4
6
8
#

' %

)
+
3
/
-
1

8
6
4

& $

* (

.
5
2 ,
7
0

9&

Port Description Location

E, F Boom up G3/8
G, H Boom down G3/8
O, P Bucket open G3/8
M, N Bucket close G3/8
C, D Arm-out G3/8
A, B Arm-in G3/8
K, L Swing left G3/8
I, J Swing right G3/8
Q Swing pressure sensor signal G1/4
U - G1/4
S Swing priority orifice switch G1/4
V - G1/4
T Return G1/4
R Heat circuit G1/4

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 8001-19
Safety valve (Option for Europe)
1. Arm

T1

T2

P1
Pi

P2

TD06014-003

Port Remarks Port size

P1 Arm HBCV SAE 6000psi 1 1/4
P2 Arm HBCV SAE 6000psi 1 1/4
Pi G3/8
T1 G3/8
T2 G3/8

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8001-20
2. Boom

U2 E
Pi1

C2
TD06014-007

Port Remarks Port size

U2 Boom HBCV SAE 6000psi 1 1/4
C2 Boom HBCV SAE 6000psi 1 1/4
T G1/4
E G1/4
Pi1 G1/4

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 8001-21
Manifolds
1. Manifold under cab

T2 T5
T1 T3
T4
P2 P5
P1 P3
P4

RST-04-06-0001O

Port Location Port Location

P1 G3/8 T1 G3/8
P2 G3/8 T2 G3/8
P3 G3/8 T3 G3/8
P4 G1/4 T4 G1/4
P5 G1/4 T5 G1/4

2. Manifold (accumulator section)

RST-04-06-0001T

Port Location
P G1/2
P1 G1/4
P2 G1/4
P3 G1/2
P0 G3/8

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8001-22
3. Manifold

B-

A
B
A-
TD06014-008

Port Location
D6, D7, D8, D9, G1/4
D1, D2, D3, T1 G3/8
T G1/2

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 8001-23
Swing motor
B
P
A
Mu

DB PA,PB

GIN

Au

Dr

SGr

TD06014-005

Port Description Location

Mu Make-up port G1-1/4
DB Drain port G1/2
P Brake release pressure supply port G1/4
A, B Main port Ø26
PA, PB Pressure measuring port G1/4
Dr Drain port PT1/2
SGr Grease-up port PT1/8
Au Air bleed port G1/4
GIN Gear oil feed port G1/2

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8001-24
Travel motor

D1

VB

VB

VA
VA

MB,MA

D2
TD06014-006

Port Description Location

D1,D2 Drain port G1/2
P Pilot port G1/4
MA,MB Pressure detection port G1/4
VA,VB Main port G1

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 8001-25
Center joint

D' C'
C
A

P
B
D T

D B A C

P'

A'
B'
C'

D'

T T
SD06012-006

Port Description Location

A' Forward right (connected to travel motor) G1
B' Forward left (connected to travel motor) G1
C' Backward right (connected to travel motor) G1
D' Backward left (connected to travel motor) G1
P' Pilot port (connected to travel motor) G1/4
T Drain port G1/2
A Forward right (connected to control valve) 500psi 1
B Forward left (connected to control valve) 500psi 1
C Backward right (connected to control valve) 500psi 1
D Backward left (connected to control valve) 500psi 1
P Pilot port (connected to control valve) G1/4

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8001-26
PREPARATION BEFORE INSPECTION

WARNING: Hydraulic fluid output under pressure can penetrate the skin. Hydraulic fluid can also cause or
infect a slight skin cut. In the event of being injured by hydraulic fluid under pressure, consult a doctor
immediately. Any delay in obtaining treatment for an injury can cause a serious infection or reaction.
Before pressurizing the circuits, make sure that all the connections are correctly tightened and that the
! hoses and pipes are in good condition. Release pressure in the circuits completely before disconnecting
pipes or carrying out any operation on the hydraulic system. Always use a small piece of cardboard or
wood to detect leaks of fluid under pressure. Never use your hands.

WARNING: Any incorrect use or mainte- WARNING: The accumulator of this machine
nance of a construction machine can cause is charged with nitrogen under pressure. In
accidents. Only persons who have read, the event of incorrect operation of the circuit,
! understood and who observe the instructions
! change the accumulator. Never attempt to
in the operator's manual are accredited to repair it. Non-observance of these instruc-
use or maintain this machine. tions and the procedure shown below can
cause serious or fatal injury.

Releasing pressure in the hydraulic system and Pressure measurement

preparations
NOTE: Operation to be carried out before every service 7. Use the service check to check the hydraulic oil
operation on the hydraulic system. temperature.
1. Position the machine on hard, flat ground.
2. Open the bucket until the cylinder rod is completely CHK MAIN 2 Baro 0 0 3 . 9 in Hg
retracted. Coolnt 0185 ˚F EngOil 0 0 0 0 psi
3. Extend the dipper until the cylinder rod is com- HydOil 0122 ˚F Bst T 0104 ˚F
pletely retracted. Lower the boom so that the end of
the dipper is resting on the ground. Lower the tool
Fuel T 0113 ˚F Air 0086 ˚F
to the ground. RST-09-01-001K
4. Check with the diagnostic display in "SP" mode that
the following values are shown. 45 to 55°C
Oil temperature
113 to 131°F
CHK MA I N 1 P1 0 1 7 4 psi
If the oil temperature is low, raise the oil tempera-
Eng 1 8 0 0 rpm P2 0 1 7 4 psi
ture according to the warm-up operation procedure
Power 0 6 0 0 mA N1 4 4 2 . 4 psi in the operator’s manual.
Flow 0 7 2 7 mA N2 5 8 7 . 4 psi 8. Lower the pilot control cancellation lever.
9. Operate each control more than 10 times in both
RST-09-01-001H
directions to release pressure in the circuits.
Eng = Engine rpm 2000 rpm 10. Press the button located on the hydraulic reservoir
breather to release pressure in the reservoir.
Power = Electric current
490 mA (operating)
value

5. Lower the engine speed to idle for 30 seconds, then

shut down the engine.
6. Turn the starter key switch to "ON", without starting
the engine.

RST-09-01-001N

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 8001-27
Procedures for pressure measurement from the monitor display
• Monitor and switch panel
4

3
1 2 5
RST-09-01-001a

1 Liquid crystal monitor 4 Design panel

2 Switch panel 5 Installation bracket
3 Hour meter
1. Pressure Measurement Method
The P1, P2, N1, and N2 pressure can be measured from the monitor display.
(The pilot pressure cannot be measured.)
2. Operating Method
If you hold down both the travel mode select switch and the horn volume select switch on the switch panel for 3 sec-
onds, the display switches to the service support screen.
The respective pressures are displayed in the service support screen's "P1" (P1 pump main pressure), "P2" (P2
pump main pressure, "N1" (N1 negative control pressure, and "N2" (N2 negative control pressure) columns.
If you again hold down both the travel mode select switch and the horn volume select switch on the switch panel for
1 second, the display returns to the normal screen.

Normal screen Service support screen

+
CHK MAIN 1 P1 0 1 7 4 psi
a Eng 1 8 0 0 rpm P2 0 1 8 8 psi
Power 0 6 0 0 mA N1 4 5 6 . 9 psi
b Flow 0 7 2 7 mA N2 5 8 7 . 4 psi

SI01009-002

a: Hold down for 3 seconds

b: Hold down for 1 second

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8001-28
Procedures for measuring hydraulic oil temperature from the monitor display
1. Hydraulic Oil Temperature Measurement Method
The hydraulic oil temperature can be measured from the monitor display.
2. Operating Method
If you hold down both the travel mode select switch and the horn volume select switch on the switch panel for 3 sec-
onds, the display switches to the service support screen.
With the travel mode select switch (mode select switch), set the mode to "CHK".
With the horn volume select switch (section switch), set the section "MAIN".
With the light switch (page +), switch to Page "2".
The hydraulic oil temperature is displayed in the "Hydoil" column.

1 3 4
MAIN/ENG...
2 5
CHK/DIAG/HR...
6

CHK MAIN 1 P1 0 1 7 4 psi

Eng 1 8 0 0 rpm P2 0 1 7 4 psi
Power 0 6 0 0 mA N1 4 5 6 . 9 psi
Flow 0 7 2 7 mA N2 5 8 7 . 4 psi

7 SI01009-003

Page switch operation

CHK MAIN 2 Baro 0 0 3 . 9 in Hg

Coolnt 0 1 8 5 ˚F Eng oil 0 1 2 4 psi
Hydoil 0 1 2 2 ˚F Bst T 0 1 0 4 ˚F
Fuel T 0 1 1 3 ˚F Air 0 0 8 6 ˚F
SI01009-004

N101005-002

1 Section 5 Page (-)

2 Mode 6 Page (+)
3 Page 7 Mode select switch
4 Section switch A Hydraulic oil temperature (°C)

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 8001-29
Pressure measuring port
There are the following three ports for measuring the pressure.
• Main pressure: pressure ports (P1, P2)
• Negative control pressure: pressure ports (N1, N2)
• Pilot pressure: pressure port (P3)

Negative control pressure

Pressure port N1, N2
(Remove the negative control pressure sensor and install the
pressure gauge.)

2 7 3

5 4

1
6 Main pressure
Pressure port P1, P2
(Remove the main pressure sensor and install the pres-
sure gauge.)

Pilot pressure
Pressure port P3
TI01011-501

1 Pump 5 Negative control pressure: N2

2 Main pressure: P2 6 Pilot pressure: P3
3 Main pressure: P1 7 Control valve
4 Negative control pressure: N1

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8001-30
Control valve
Location of relief valves
Tools Pressure per
rotation of Measuring
Position Set pressure
Lock nut Adjusting screw adjusting port
screw
22 mm 19 mm 31.4 MPa 21.3 Mpa
a Main (normal use) Monitor P1
0.87 in 0.75 in 4554 Psi 3089 Psi
1
Main (boosted 32 mm 26 mm 34.3 Mpa 25.7 Mpa
b Monitor P1
pressure) 1.26 in 1.02 in 4975 Psi 3727 Psi
17 mm 6 mm 36.3. Mpa 21.3. Mpa
2 Boom-up Monitor P2
0.67 in 0.24 in 5265 psi 3089 psi
22 mm 8 mm 24.5Mpa 13.1 Mpa
3 Boom down Monitor P2
0.87 in 0.31 in psi 1900 psi
4 Arm-in Monitor P1
5 Arm-out 17 mm 6 mm 36.3. Mpa 21.3 Mpa Monitor P1
6 Bucket close 0.67 in 0.24 in 5265 psi 3089 psi Monitor P2
7 Bucket open Monitor P2
24 mm 6 mm 3.92 Mpa 2.0 Mpa
8 Pilot
0.94 in 0.24 in 569 psi 290 Psi

4
5
7
6

3
2

1
8 2
4
3

TI01011-001

Main relief valve adjustment location details

1 Boosted pressure lock nut 3 Standard pressure adjusting screw
2 Boosted pressure adjusting screw 4 Standard lock nut

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 8001-31
PRESSURE MEASUREMENT
Main Pressure Measurement
Pressure gauge installation
1. Install pressure gauges at the pump pressure mea- 3. Install adapter (3).
suring ports.
(Pressure ports: a1 / a2)

a2
3
a1

TI01011-503
TI01011-505

a1: Can be measured a2: Can be measured 4. Install pressure gauges (4) on the adaptor (3) and
fasten it.
Travel left Travel right
Option Bucket
Swing
Arm 1 pump flow Arm 2 pumps flow
Boom 2 pumps flow Boom 1 pump flow

2. Remove the plug (2).

TI01011-506

TI01011-504

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8001-32
Attachment pressure measurement
Example: Arm-out pressure measurement
Measure with the following operations.

Engine speed 2000 min-1

Work mode SP mode
1
Lever operation Arm-out relief
Oil temperature 45 - 55°C
Measuring port 1 pump: P1 port
2 pumps: P2 port
Set pressure Boosted pressure: 34.3 MPa (4975
Psi)
Standard: 31.4 MPa (4554 psi)
1 Arm-out relief
When the attachment operates, since the pressure boost operates automatically, the set boosted pressure can be
checked for about 8 s. After 8 s or more, the standard set pressure can be checked.
Measure relieving each cylinder with the arm out/in, the bucket open/close, and the boom up.

Lever operation Arm out Arm in Bucket Bucket Boom up Boom down
open close
Engine speed 2000 min-1
Work mode SP mode
Oil temperature 45 - 55°C (113 to 131°F)
1 pump flow P1 P1 P2 P2 P2 P2
measuring port
2 pumps flow P2 P2 No No P1 No
measuring port
Boosted pressure 34.3 MPa 34.3 MPa 34.3 MPa 34.3 MPa 34.3 MPa 24.5 MPa
4975 Psi 4975 Psi 4975 Psi 4975 Psi 4975 Psi 3553 Psi
Standard pressure 31.4 MPa 31.4 MPa 31.4 MPa 31.4 MPa 31.4 MPa 24.5 MPa
4554 Psi 4554 Psi 4554 Psi 4554 Psi 4554 Psi 3553 Psi
Boom-down pressure measurement
For pressure measurement with the boom down,
put the arm cylinder at its out stroke end, open the
bucket, put the bucket tip on the ground, carry out
the boom-down operation, and measure.

2 Boom-down relief

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 8001-33
Travel pressure measurement
1. Install the stopper (5) on the crawler sprocket (6) 2. Measure with the following operations
section and lock the travel motor.
Engine speed 2000 min-1

6 5 Work mode SP mode (1st speed)

Lever operation Travel relief
45 to 55°C
Oil temperature
113 to 131°F
Left travel: P1 port
Measuring port
Right travel: P2 port
34.3 MPa
Set pressure
4975 Psi

RST-09-01-001W

Swing pressure measurement

1. Set the swing lock with the monitor. 2. Measure with the following operations

Engine speed 2000 min-1

Work mode SP mode
Lever operation Swing relief
45 to 55°C
Oil temperature
113 to 131°F
Measuring port P1 port
29.4 MPa
Set pressure
4264 Psi

3. After the end of pressure measurement, release

the swing lock with the monitor.
RST-09-01-001X

Swing lock switching

In order to prevent accidental operation under certain special circumstances, sometimes the swing brake need to be
left ON all the time. (Swing lock) At this time, you can switch the swing lock ON to OFF or OFF to ON by holding
down the "horn volume select switch", the "working light switch", and the "auto idle switch" at the same time for 2
seconds. When the swing is locked, an icon "P" appears on the liquid crystal monitor.

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8001-34
Option line pressure measurement
1. Close the option line stop valve (7). 3. Measure with the following operations.

Engine speed 2000 min-1

Work mode SP mode
Pedal operation Option relief
Oil temperature 45 to 55°C
1 Pump: P2 port
Measuring port
2 Pumps: P1 port
* 17.7 MPa
Set pressure
* 2567 Psi

* Adjust the set pressure to match the specifica-

tions of the attachment used.
7 Factory Pressure Settings
Breaker circuit: 17.7 MPa (2567 Psi)
RST-09-01-001Y Shuttle, combine (crusher) circuit: 27.5 MPa (3989
2. With the option operation select switch in the cab, Psi)
switch to the option line to measure. (Breaker, shut-
tle).

RST-09-01-001Z

Lep SM470B8001-0NA Issued 07-08

 8001-35
Pilot pressure measurement
Pressure gauge installation
1. Install a pressure gauge at the pump pressure 3. Install the pressure gauge (10) and measure the
measuring port. (Pressure port: P3). pressure.

10
P3

TI01011-509

Engine speed 2000 min-1

TI01011-507 Work mode SP mode
2. Install the adapter (9). 45 to 55°C
Oil temperature
113 to 131°F
Measuring port P3 port
3.9 Mpa
Set pressure
566 psi

TI01011-508

Lep SM470B8001-0NA Issued 07-08

8001-36
Negative pressure measurement
Pressure gauge installation
1.Remove the pump N1 or N2 pressure sensor connector (11), and remove the pressure sensor. (N1, N2: pressure port)
(The pressure sensor location becomes the measurement port.)

11

N2
11
N1

TI01011-510

2.Install the adaptor (12) for pressure gauge, and install the pressure gauge (14) at the port from which the N1 or N2
pressure sensor (11) was removed. Measure the negative control pressure for each operation.

14

12
12 14

TI01011-512

Engine speed 2000 min-1

Work mode SP mode
Oil temperature 45 to 55°C
P1 pump side: N1 port
Measuring port
P2 pump side: N2 port
3.4 MPa max.
Set pressure 493 Psi max.
(Non operation)

Lep SM470B8001-0NA Issued 07-08

 8001-37
PRESSURE ADJUSTMENT
Main pressure adjustment
Adjustment preparation work
Pressure is adjusted with control valves.
The following preparations are required for adjusting with control valves.
1. Pull the engine hood lock release lever (2) to 2. Remove the screws (4), then remove the cover (5).
release the lock.

5
4

2
TI01011-513

Open the engine hood(1).

TI01011-515
At this time, always check that the lock (3) is locked.
3. Remove the 7 bolts (6), then remove the bottom
cover (7).

1 6

3
TI01011-519

TI01011-514 4. Remove the 7 bolts of the center cover (8) inside

the housing, and then remove the cover.

TI01011-004

Lep SM470B8001-0NA Issued 07-08

8001-38
Main relief pressure adjustment
3. Standard pressure
Engine speed 2000 min-1 H Loosen the standard pressure lock nut (11) (22
Work mode SP mode mm, 0.87 in).
Lever operation Arm-in relief I Loosen the adjusting screw (10), lower below the
set pressure, then adjust on the tightening side.
45 to 55°C
Oil temperature J After adjustment, tighten the lock nut (11) while
113 to 131°F
fastening the adjusting screw (10) with a spanner.
Measuring port P1 port
K After locking, check the pressure. Repeat H), I),
Boosted pressure: and J) until the set pressure is correctly adjusted.
34.3 MPa L Stop the engine.
4975 Psi
Measurement pressure
Standard:
31.4 MPa
4554 Psi
Boost pressure:
21.3 MPa / rotation
Pressure per rotation of 3089 Psi / rotation
adjusting screw Standard:
25.7 MPa / rotation
3727 Psi / rotation

1. Before adjusting, remove the pilot hose for the

boosted pressure signal connected to the main
relief valve (7), then plug the hose side. The proce-
dures for boosted pressure and standard pressure
are different.
2. Boosted pressure
A Loosen the standard pressure lock nut (11) (22
mm, 0.87 in) and tighten the adjusting screw (10) (19
mm, 0.75 in). Fasten with a spanner (26 mm, 1.02 in) so 7
that the boosted pressure adjusting screw (9) does not
turn.
B After tightening until the adjusting screw (10) stops
turning, tighten the lock nut (11).
C Start the engine and run it at maximum rotation.
D Move the arm lever to the in side, set the relief
state, and hold.
E Loosen the boosted pressure lock nut (8) (32 mm,
1.26 in) and adjust the set pressure with the adjusting
screw (9) (26 mm, 1.02 in).
• When lower than the set pressure, tighten. 11
10
• When higher than the set pressure, first lower below
the set pressure, then adjust on the tightening side.
F After adjustment, fasten the adjusting screw (9)
with a spanner (26 mm, 1.02 in), then tighten the lock
nut (8).
G After locking, check the boosted pressure side
pressure. Repeat A) to F) until the set pressure is cor-
rectly adjusted.

8 9
TI01011-002

Lep SM470B8001-0NA Issued 07-08

 8001-39
Overload relief pressure adjustment

Engine speed 2000 min-1 6 Control valve

Work mode SP mode 12 Boom-up
45 to 55°C 14 Bucket-open
Oil temperature
113 to 131°F 16 Bucket-close
Measuring port P1 / P2 port 21 Arm-in
Boom down:
24.5 MPa
3553 Psi 13
Measurement pressure
Others: 21
36.3 MPa
5265 Psi
Boom down
13.1 MPa / rotation
Pressure per rotation of 1900 Psi / rotation
adjusting screw Others:
21.2 MPa
3075 Psi

1. Since the overload relief pressure is set higher than

the main relief pressure, it is necessary to provi- 6
sionally set the main relief pressure higher than the
overload relief pressure. (Except for boom down)
2. Main Relief Pressure Provisional Setting
• Using the main pressure adjustment procedure for
reference, temporarily set the boosted pressure and
standard pressure to at least 36.3 MPa (5265 Psi).
NOTE: For boom down (15), since the overload set
pressure is lower than the main relief set pressure,
there is no need to temporarily set the main relief pres-
sure. 16 14
3. Pressure adjustment
NOTE: For the position of each overload relief, see the
"Control Valve Relief Locations".
Example: Arm-out (13) overload relief adjustment
A Loosen the lock nut (17) and adjust by the turning
the adjusting screw (18).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first loosen to a
pressure lower than the set pressure, then adjust on
the tightening side.
B After adjustment, lock the lock nut (17).
C After adjusting the overload relief pressure, adjust 12 15
the boosted pressure and standard pressure to their
normal values referencing the main pressure adjust-
ment procedure.

17 18
TI01011-003

Lep SM470B8001-0NA Issued 07-08

8001-40
Swing relief pressure adjustment
Pilot pressure adjustment
Engine speed 2000 min-1
Work mode SP mode Engine speed 2000 min-1
45 to 55°C Lever operation Neutral
Oil temperature
113 to 131°F
Measuring port P3
Measuring port P1 port
3.9 MPa
Set pressure
29.4 MPa 566 Psi
Measurement pressure
5714 Psi
Pressure per rotation of 4.8 MPa/rotation 1) Pressure measurement
adjusting screw 696 Psi/rotation a) Install the pressure gauge (28).
b) While holding the plug with a wrench (26), adjust with
1. Using the swing pressure measurement procedure a hexagon wrench (27).
for reference, lock the swing, and check the swing
pressure.

28

29
25
27

TI01011-516

26

26

TI01011-518

27

TI01011-517

2. Loosen the lock nut (25) and adjust by turning the

adjusting screw (29).
• When lower than the set pressure, tighten.
• When higher than the set pressure, first loosen to a
pressure lower than the set pressure, then adjust on
the tightening side.
3. After adjustment, lock the lock nut (25).

Lep SM470B8001-0NA Issued 07-08

 8001-41
HYDRAULIC PUMP FLOW MEASUREMENT PROCEDURE
Work preparations
1. Check that the main unit is in its work posture (arm- 4. Use the bolts removed in step 3 to install the
vertical). hydraulic oil tank lid (3).

S109006-001
2. Bleed out the pressure. (See the details on Bleed-
TI02008-502
ing Pressure in the Pressure Measurement and
Adjustment Procedures.) 5. Install the vacuum pump (4) on the hydraulic oil
tank lid.
NOTE: Check the swing stop.
3. Use a spanner (17 mm, 0.67 in) to remove the feed
port cover (2).

TI02008-503

TI02008-501

Lep SM470B8001-0NA Issued 07-08

8001-42
6. After setting the vacuum pump (4), switch on the 8. Remove the 6 bolts (4), then remove the cover (5).
power. (If the cable is too short, use an extension
cable.)

4
5
4

TI01011-515

9. Remove the hose (9) between the hydraulic pump

and line.
TI02008-504

7. Pull the engine hood lock release lever (1) to

release the lock.

10

11 9
12

TI02008-505
2
TI01011-513

Open the engine hood (1).

At this time, always check that the lock (3) is locked.

9 10 11 TI02008-001

TI01011-514

Lep SM470B8001-0NA Issued 07-08

 8001-43

13

14

c 19

b 15

14
16

18 13
17
TI02008-506

a Procedure 10 - 12 16 Flow meter

b Procedure 14
c Procedure 10, 11, 13
15 Hydraulic hose for flow measurement (IN)
10. Install the adapter (13) at the position (pump or
line) which the hydraulic hose (9) was removed.
11. Install the elbow adapters (14) on either side of the
2 hydraulic hoses for flow measurement.
12. Use a wrench to install the elbow adapter (14) side
on the hydraulic hose for flow measurement to the
adapter (13) on the pump side.
13. Use a wrench to install the elbow adapter (14) side
on the hydraulic hose for flow measurement to the
adapter (13) on the line side.
14. Use a wrench to install the hydraulic hose for flow
measurement on the pump side to the flow meter
IN side and the hydraulic hose for flow measure-
ment on the line side to the flow meter OUT side.
• When connecting, always check the connection posi-
tions.
• Always have the orifice fully open.
17 Orifice
18 Hydraulic hose for flow measurement (OUT)
19 Line
15. Install pressure gauges on P1 and P2.
(See "Main Pressure Measurement".)
16. Remove the vacuum pump and re-install the
hydraulic oil tank the same way it was.
17. Remove the pilot hose for the pressure boost sig-
nal, then plug the hose side.
(See "Main relief pressure adjustment".)
This completes the preparation for flow measure-
ment.

Lep SM470B8001-0NA Issued 07-08

8001-44
Flow measurement
1. When measuring the flow, position the workers as 3. Check the hydraulic oil temperature on the monitor
in the figure below. (50°C, 122°F). Check that the engine rotation and
• Worker 1: Work supervisor, pressure adjustment pump current are normal.
• Worker 2: Operator 4. The operator signals the arm-out relief operation to
• Worker 3: Flow, pressure measurement, recording worker 1.
5. Worker 2 lowers the arm-out port relief. (Min: 24
MPa (240 bar, 3481 Psi) (P1 + P2)
1
6. Start of flow measurement.
7. The arm-out relief operation is carried out.
3 8. Data measured in units of 2.0 MPa (20 bar, 290Psi)
(P1 + P2).
2
• The measurement is carried out from 24.0 to
69.0 MPa (240 to 690 bar, 3481 to 10008 Psi) and
ends when the maximum pressure is reached.
9. Remove the flow meters.
• Because from 40 MPa (400 bar, 5802 Psi) the pres-
sure exceeds the permitted value for the flow meter
pressure gauge maximum pressure.
10. Reset the arm-in port relief valve to normal pres-
RST-09-02-001I sure. (For details on this adjustment, see "PRES-
2. At the signal from the work supervisor, the operator SURE ADJUSTMENT".)
starts the engine. 11. Remove the pressure gauges etc. and put every-
thing back to normal.

4
SP

RST-09-02-001J

Lep SM470B8001-0NA Issued 07-08

 500
Flow curve

Lep SM470B8001-0NA
400
20.2 MPa
354 L

Q 1980 min-1

33.4 MPa
348 L
300
0.66 ±0.1 MPa
355 ± 3 L 33.8 MPa 47.0 MPa
238 L 233 L

Pi-Q curve (1980 min-1)

Flow rate Q [L/min]

200

146 L

3.2 ± 0.2 MPa

61 ± 3 L
100
98 L
Pd = 7.8 MPa at Qmax

0
0 10 20 30 40 50 60 [MPa]
Delivery pressure Pd

0 1 2 3 4 [MPa]
Pilot pressure Pi

TC01015-001

Issued 07-08
8001-45
8001-46
DRAIN VOLUME MEASUREMENT PROCEDURE
Preparations
Measuring conditions

Engine speed 2000 min-1

Mode SP mode
About 50°C
Oil temperature
About 122°F

WARNING: The drain volume varies greatly with the oil temperature.

Travel motor drain volume measurement

1. Ground the arm as in the figure below, then make 3. Always lay a rag (6) underneath before removing
the shoe crawler on one side float. the drain hose (5).
4. Use a spanner to remove the drain hose (5).
(Always install a cap on the drain hose.)

RST-09-03-001A
2. Remove the bolts (4), then remove the cover (3).

6 SI03008-501

5. Install the extension hose (7) for measurement on

the side of the motor from which the drain hose was
removed.

4 RST-09-03-001b

SI03008-502
7

Lep SM470B8001-0NA Issued 07-08


6. Prepare a waste oil receiver (8) and measuring
container (9) and set them as in the figure below.
8001-47
8. In SP mode at medium speed, relieve the travel
operation and at the same time the motor starts,
move the extension hose to the measuring con-
tainer (9).
(When the motor starts, start measurement with a
stop watch (11).)
9. After 30 seconds, move the extension hose to the
waste oil can (8).
10. Measure the volume of oil in the measuring con-
tainer as the drain volume for 30 seconds.

Forward Backward
1st 2nd 1st 2nd
speed speed speed speed
Right
Left

• Measure at least three times each for left, right,

8 9 advance, and retreat.
SI03008-503

7. Catch the stopper (10) between the sprocket sec-

tion and the frame and lock the travel motor.

10

30 seconds

9
8
1
10 SI03008-504

RST-09-03-001f

Lep SM470B8001-0NA Issued 07-08

8001-48
Swing motor drain volume measurement
1. Remove the two drain hoses (1) and put blind plugs 3. Prepare a waste oil receiver (6) and measuring
in the hose side of each. container (5) and set them as in the figure below.

3
1

1 60 seconds

TI03010-501

2. Install the extension hose (3) for measuring the
drain volume on one side of the T nipple. Install the
hose facing in a direction that makes measurement
easy and install a blind plug (2) on the other side.
3
2
TI03010-502
4 5 6
RST-09-03-001J
4. In SP mode, relieve the swing operation and at the
same time the motor starts, move the extension
hose (3) to the measuring container (5).
(When the motor starts, start measurement with a
stop watch (4).)
For details on the method for locking the swing
motor, see "Swing relief pressure adjustment".
5. After 60 seconds, move the extension hose (3) to
the waste oil receiver (6).
6. Measure the volume of oil in the measuring con-
tainer (5) as the drain volume for 60 seconds.
• Measure at least three times each for left and right.
Right Left

Lep SM470B8001-0NA Issued 07-08

 8001-49
AIR BLEED PROCEDURE

WARNING: Always bleed off any air in the hydraulic circuits after replacing the hydraulic oil, repairing or
! replacing hydraulic equipment, or removing hydraulic pipes.

Air bleed procedure mode (when bleeding, follow the procedure below
Hydraulic pump air Cylinder air Swing motor air Travel motor air
Check
bleeding bleeding bleeding bleeding
Hydraulic oil or
hydraulic pump
replacement
Cylinder
replacement
Swing motor
replacement
Travel motor
replacement

NOTE: Failure to completely bleed off all the air can reduce the service life of hydraulic equipment and lead to damage.

Hydraulic pump
1. Loosen the air bleed plug (1) and check that oil
oozes from the air bleed port (2).
2. If oil does not ooze out, remove the air bleed plug
(1), and fill hydraulic oil (3) from the air bleed port
(2) into the pump case.
3. Temporarily tighten the air bleed plug (1).
2
4. Run the engine at low idle, slightly loosen the air 4
bleed port, and run until oil oozes from the air bleed
port section.
5. Completely tighten the air bleed plug (1).
1

TI04011-501

Lep SM470B8001-0NA Issued 07-08

8001-50
Travel motor
1. Remove the bolt (2), then remove the cover (1). 3. Fill hydraulic oil (5) from the drain port.

5
1

RST-09-04-001c
2
SI04009-003
2. Remove the hose (3) of drain port and elbow (4).
4. When inside the motor is filled with hydraulic oil (5),
3 4 tighten the elbow and hose.
5. Start the engine and execute a slow travel opera-
tion.
6. Repeatedly travelling forward and backward bleeds
off the air.

SI04009-002

Lep SM470B8001-0NA Issued 07-08

 8001-51
Swing motor
1. Run the engine at low idle, loosen the air bleed plug
(2), and check that oil oozes from the air bleed port
section.
• Do not execute a swing operation.
2. If oil does not ooze out, stop the engine for now, 2
remove the air bleed plug, and fill hydraulic oil into
the motor case.
3. Temporarily tighten the air bleed plug.
4. Run the engine at low idle, slightly loosen the air
bleed port (4), and run until oil oozes from the air
bleed port (4) section.
5. Completely tighten the air bleed plug.
6. With the engine at low idle, slowly swing evenly left
TI04011-502
and right at least two rotations.
Check
After the air bleeding is complete, stop the engine 3
for at least five minutes to allow any air bubbles in
the hydraulic oil tank to dissipate.

TI04011-503

Lep SM470B8001-0NA Issued 07-08

8001-52
Safety valve

WARNING: The safety valve air bleeding work requires two workers: an operator and an air bleed worker.
Decide your signals beforehand and work safely. Set the main unit so that the arm safety valve is at the
! highest position. (See the figure below.)

Boom cylinder safety valve

1. Start the engine and lower the boom without jack-
ing up the main unit.
2. In the above state, loosen the hose mouthpiece (1) 1
at the position in the figure.
3. Foaming hydraulic oil comes out from the hose
coupling section.
When foaming hydraulic oil stops coming out,
tighten the hose mouthpiece (1).
4. Execute steps 2 and 3 for the opposite side boom
cylinder too. HBCV
5. Check boom operations. If there is a delay in the
operation response, bleed the air again with the
same procedure.

TI04011-504

Arm cylinder safety valve

1. For arm-in operations, bleed the air from the arm
cylinder safety valve using the same procedure as
for boom cylinder safety valve air bleeding. 1

HBCV

TI04011-505

Lep SM470B8001-0NA Issued 07-08