LHEX - Commissioning & Performance Test Form

COMMISSIONING UNIT/DEALER INFORMATION 2

FLUID LEVELS CHECK: 2

NOTE: 2
NOTE: 2
NOTE: 3
FLUID LEVELS CHECK: 3
AUTO LUBE (GREASE) CYCLE: 4
NOTE: 4
VITAL INFORMATION MANAGEMENT SYSTEM (VIMS) 4
NOTE: 4
MACHINE SYSTEMS CHECK: 5
CYCLE TIMES & DRIFT RATES 7
NOTE: 7
TRACK ROLLER BREAK-IN PROCEDURE 9
TRAVEL PROCEDURE 9
PERFORMANCE TEST 10
INTRODUCTION: 10
PROCEDURE 10

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COMMISSIONING UNIT/DEALER INFORMATION

Date: 7/15/02 Dealer: Hewitt
Machine Model: 5130B Dlr Code:
Serial Number: 4CS00200 Customer: McWatters
SMU: 16.2 Configuration: ME FS
Completed by: D.L. Hamilton Job Site: Sigma Mine Quebec, Ca.
Unit Number: 201

The following document is to be used by service personnel at the completion of assembling a

Caterpillar Large Hydraulic Excavator. Use current service literature, as a reference guide to
perform the testing and adjusting procedures required gathering the data for this form.

FLUID LEVELS CHECK:

Note:
Use Operation & Maintenance Manual to reference oil level and viscosity recommendations.

Coolant: o Pump Drive: o Windshield Reservoir: o

k k k
Hydraulic Oil: o Engine Oil: o Auto Lube (Grease): o
k k k
Swing Drives: o Final Drives: o
k k

Note:

When conducting initial start up and hydraulic testing and adjusting, ensure the following has
been completed:

1. _____ Perform fuel system dry start procedure.

2. ______ Open 2 heater valves on the engine.
3. ______ Remove case drain line from fan pump for hydraulic oil cooler and bleed air from
pump.
4. _____ Remove case drain line from engine fan pump & bleed air from pump.
5. _____ Remove case drain line from all 4 imp pumps removing the line that is furthest away
from the hydraulic tank, bleed all case drain lines.
6. _______ Remove case drain line from swing pump and bleed air from pump.
7. _______ Remove case drain line from swing motor and bleed air from pump.
8. _______ Remove case drain line from travel motors and bleed air from motor.
9. _______ Remove case drain line from a/c compressor motor and bleed air from motor.
10. _______ Remove case drain line from hydraulic oil cooler fan motor and bleed air from
motor.
11. _______Prime the implement and swing pumps with oil to reduce the possibility of pump

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cavitation. Crank the engine and have another person hold the remote engine stop switch in
the stop position. Do this two or three times before allowing the engine to start.
12. _______ After the initial start up shut the engine down and perform a visual inspection of
the hydraulic system for leaks.
13. _______ When satisfied that the hydraulic pumps have been primed, start the engine with
the throttle control in position 1 (low idle).
14. _______ Bleed the control valves end housings at the bleed screws one at a time to remove
all the air from the housings.
15. ______ While maintaining low idle; perform the "Hydraulic Cylinder Start-Up Procedure".
16. _______ When satisfied that all the air has been removed from the hydraulic system, select
throttle position 10 (high idle) and stall the implements several times to increase the oil
temperature for testing. Maintain the hydraulic oil temperature at 40o C (100o F) minimum
when performing testing and adjusting.
17. _______ At completion, clean oil spillage, check hydraulic oil level and inspect thoroughly
for leaks.

Note:
Maintain the hydraulic oil temperature at 38o C (100o F) minimum when performing testing and
adjusting.

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AUTO LUBE (GREASE) CYCLE:

Before sending the machine to work, set the Lube Cycle Time to the 5-minute interval. Be satisfied
that all automatic grease points are receiving sufficient quantity of grease. Adjust grease injectors
as required.

Observe the grease points during machine operation and adjust the Cycle Time and injector settings
to suit the site conditions. Obtaining satisfactory balance of the cycle time and the injector settings
must be established through observation.

Note:
For detailed instructions refer to Automatic Lubrication System Service Manual and VIMS Service
Manual and Operation & Maintenance Manual

VITAL INFORMATION MANAGEMENT SYSTEM (VIMS)

Note:
For detailed instructions refer to VIMS Service Manual and Operation & Maintenance Manual.

When assembling is complete and prior to performing Machine System Checks, ensure that the
source code and/or configuration software is installed. An error message will be shown on the
message center if this problem exists. Upload source code and/or software configuration if
required.

During assembly it is probable that a Category 1,2 & 3 Warnings were activated. If this has
occurred it will be necessary to clear the following:
• Event List Statistics
• Event Recorder
• Blue Service Light

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MACHINE SYSTEMS CHECK:

ITEM DESCRIPTION SPECIFICATION ADJUST ACTUAL

REQ'D Y/N
1 Engine Throttle Position 10 1810 + 20 rpm no
1805
2 Engine Throttle Position 1 725 + 20 rpm no
728
3 Implement pilot system accumulator Refer ambient
pre-charge temp chart
4 Track tension accumulator pre- Refer ambient
charge temp chart
5 Pilot System

Track Tension Pilot pressure 7000 + 200 kpa no

@ Throttle position 10, no implements stalled (1015 +30 psi) 1030
Implement Pilot Pressure 4500 + 200 kpa no
@ Throttle position 10, no implements stalled (650 + 30 psi) 666

Implement pilot oil pressure > 3 445 kpa no

@ Throttle position 1 (no stall) (> 500 psi) 656
(must be >500 psi)
Power Shift Calibration:
Always run calibration program after adjusting pilot relief pressures or reloading software.
8 Dual load sensing signal relief
valve. @ Throttle position 10 with implement
stalled. Stall and check travel circuit first, then the
bucket circuit.
Travel 34000+ 1000 kpa
(Check and adjust travel circuit first)
(4930 + 145 psi) no 5050
Implement 31000 + 500 kpa
(4500 + 70 psi) no 4550
9 Margin Relief Valve 3000 ± 350 kpa
@ Throttle 4 Isolate pumps, connect PS to one pump,
(435 ± 50 psi) no 445
adjust margin screw until margin valve opens.

9A Margin Pressure @ Throttle 10 1900 – 2000 kpa

Stall Bucket Dump (275 – 300 psi)

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LF 295
LR 280
RF 280
RR 280
9B De-stroke
Throttle 1
Powershift 1380 kpa ( 200 psi)
Initiation point 15500 +0/-300 kpa
2250 +0/- 45 psi

LF 150
LR 150
RF 150
RR 150
9C Combined implement margin 2050 + 150 kpa
(differential) pressure * (290 + 15 psi)
(Throttle position 10, stall bucket,
pumps not isolated)
10 Swing dual pressure relief valve
@ Throttle position 10
10A ACCELERATION 34000+1000 Kpa 5140
(4930 + 145 psi)
10B DECELERATION 28500 + 500 Kpa 4250
Disconnect the signal line. (4130 + 70 psi)
11 Engine cooling fan speed (Throttle
position 10)

11A 0% Bypass
970+ 10 rpm 5130B 963
850+ 10 rpm 5230
11B 100% Bypass approx. 375 rpm N/A
12 Engine cooling fan pump
discharge pressure (Throttle
position 10)

12A 0% Bypass
<16 000 Kpa N/A
(<2320 psi)
12B 100% Bypass < 4 000 Kpa N/A
(< 580 psi)
12C Margin pressure @ 100% Bypass 2100 Kpa + 100
(305 + 15 psi)
13 Hydraulic cooling fan speed
(Throttle position 10)
13A 0% Bypass 950 + 10 rpm 5130B 950
5230
13B 100% Bypass approx. 485 rpm N/A

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14 Hydraulic cooling fan pump

discharge pressure (Throttle
position 10)
14A 0% Bypass <9 000 Kpa N/A
(<1 300 psi)
14B 100% Bypass < 4 000 Kpa N/A
(< 580 psi)
14C Margin pressure @ 100% Bypass 2100 Kpa + 100
(305 + 15 psi)

CYCLE TIMES & DRIFT RATES

Note:

For specifications, refer to service manual of the machine model. Enter the specification in the
specification column.

ITEM DESCRIPTION SPECIFICATION ADJUST ACTUAL

REQ'D Y/N
15 Travel time @ Throttle position 328 ft / 95 –129
10, both pedals fully depressed, on sec.
flat level ground. (100 m)

15A Travel drift rate @ Throttle position 26 ft in 328 ft.

10, both pedals fully depressed, on (8m / 100m)
flat level ground.
16 Implement cycle times @ Throttle
position 10 (pg 7 Testing and
Adjusting)
16A BOOM RAISE Extension of the boom cyl. FS 7.4 + 1 8.0 sec
Bucket on the ground. Stick and bucket cyl extended. ME 7.4 + 1
16B STICK IN Extension of the stick cylinder. FS 5.2 + 1 7.7 sec
Boom up and bucket curled just enough to clear the ME 7.4 + 1
ground.
16C STICK OUT Retraction of the stick cylinder. FS 6.7 + 1 5.7 sec
Boom up and bucket curled just enough to clear the ME 6.7 + 1
ground.
16D BUCKET LOAD Extension of the bucket cyl. FS 5.1 + 1 5.6 sec
Boom and stick in at rest position, boom up to clear the ME 5.4 + 1
ground.
16E BUCKET DUMP Retraction of the bucket cyl FS 2.2 + 1 2.6 sec
Boom and stick in at rest position, boom up to clear the ME 2.4 + 1
ground.
16F BOTTOM DUMP OPEN Retraction of FS 1.9 + 1
the bottom dump cylinder.
Boom and stick in at rest position, boom up to clear the
ground.

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16G BOTTOM DUMP CLOSE Extension of FS 2.5 + 1

the bottom dump cylinder.
Boom and stick in at rest position, boom up to clear the
ground.
17 Swing speed @ Position 10. Start with 1 Rev = 15 sec 1 rev =14.57 sec
the upper structure in motion. 3 Rev = 41 – 53 3 rev = 44 sec
sec
17A Swing speed @ Position 10, AESC 7.3 sec 6.4 sec
on, for 90 degrees.
18 Swing Coast < 45o Less than 25
19 IMPLEMENT DRIFT RATES 0 = boom
Stall implement, wait 5 minutes, stall 1.75” = stick
implement again, measure 1” = bucket
movement.
19A BOOM CYLINDER Start with stick and 2 in / 5 min
boom cylinders at full extension.

19B STICK CYLINDERS Start with stick FS 1.5” / 5 min

cylinders in fully extended position for FS and retracted ME 2.4”/ 5 min
for ME.
19C BUCKET CYLINDERS Start with bucket FS 1.5” / 5 min
cylinders at full extension. ME 2” / 5 min
20 Verify dead engine boom lower ok
function. ( Key on, lock forward,
boom lower; boom should lower)
Machine will be used to load rock into fleet of 777D
Trucks at a open pit gold mine.

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TRACK ROLLER BREAK-IN PROCEDURE

The following procedure provides a break in period for the track rollers, carrier rollers and idlers.

This document supersedes all previous published documents and recommended practices.

A 123-6700 Infrared Thermometer II, or equivalent tool, is required to monitor component

temperatures when performing this procedure.

This procedure must be performed at machine commissioning and when track rollers, carrier rollers
and idlers have been replaced or overhauled.

When performing track roller break-in:

1. Raise the boom to max height - FS & ME.
2. Retract stick - FS & ME.
3. Curl bucket out - FS.
4. Curl bucket in - ME.
5. Travel on a level surface.
6. If a level surface is unavailable for twenty minutes travel time, travel with the sprocket facing
in the downhill direction.

7. Travel the machine in the forward direction (over idler) for twenty minutes. Monitor the
temperature of the components, several times, while the break-in procedure is being
performed. The temperature should not exceed 70o C (160o F). Check temperatures at the
roller flanges, as close to the seal as possible, and at the end of the shafts. Stop the machine
after twenty minutes of travel and inspect for oil leaks. Allow the components to cool if
required before proceeding.

Stop the machine after twenty minutes of travel and check temperatures and inspect for oil
leaks.

Travel the machine in reverse (over sprocket) for twenty minutes. Monitor the temperature of
the components, several times, while the break-in procedure is being performed. The
temperature should not exceed 70o C (160o F). Check temperatures at the roller flanges , as
close to the seal as possible, and at the end of the shafts. Stop the machine after twenty minutes
of travel and inspect for oil leaks. Allow the components to cool if required before proceeding.

Stop the machine after twenty minutes of travel and check temperatures and inspect for oil
leaks.
Repeat steps 1 through 7.

TRAVEL PROCEDURE

The following procedure is to prevent overheating the track rollers, carrier rollers and idlers when

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moving the machine over long distances.

This document supersedes all previous published documents and recommended practices.

A 123-6700 Infrared Thermometer II , or equivalent tool, is required to monitor component

temperatures when performing this procedure.

When traveling the machine over a long distance:

• Raise the boom to max height - FS & ME.
• Retract stick - FS & ME.
• Curl bucket out - FS.
• Curl bucket in - ME.
• Travel in the forward direction (over idler) except when traveling down hill. When traveling
downhill, position the sprocket on the down hill side.
Monitor the temperature of the components while the machine is traveling. Monitor the
temperature of the components, several times, while travel is being performed. The temperature
should not exceed 70o C (160o F). Check temperatures at the roller flanges , as close to the seal
as possible, and at the end of the shafts. Stop the machine after twenty minutes of travel and
inspect for oil leaks. Allow the components to cool if required before proceeding.

PERFORMANCE TEST

Introduction:

The purpose of the performance test is to establish a footprint or reference of the machine systems
being monitored by the Vital Information Management System (VIMS). Performance of this
procedure must only be performed when personnel are satisfied that all system checks and
adjustments have been satisfactorily completed. It is also recommended that the machine be put to
work for a minimum of one hour prior to recording and downloading data. Implement this
procedure immediately after working the machine.

The Data Logger is able to record 30-minute window of data. It is necessary to complete the
following procedure within this 30-minute window. If the test is not completed in the sequential
order it will need to be repeated.

PROCEDURE

1. Position the machine on a level surface and shut down the engine.
2. Perform pre-start checks as per Operation & Maintenance Manual.
3. Ensure fuel tank has an 80% or greater fuel level.
4. Paint a mark on the RH track above final drive.
5. Paint a mark on the LH track above idler.
6. Start the machine and position boom over the idlers.
7. Ensure AESC switch is off.
8. Reset the Data Logger with the keypad. Service program code: 35737 (DLRES)
9. Fully extend the Stick, Curl Bucket Out, Bottom Dump Open (FS), and lower the Boom

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until the bucket is at a height to be able to Curl In when required.

10. Select throttle position 1.
11. Start the Data Logger. Service program code: 3564 (DLOG) Hit “OK”
12. Wait 30 seconds then select all throttle positions in sequence pausing for 30 seconds
between each position. When completed, leave throttle position in position 10.
13. Stall the Bottom Dump, Out, for 15 seconds. (FS only)
14. Stall the Bottom Dump, In, for 15 seconds. (FS only)
15. Stall Bucket, Curl Out, for 15 seconds.
16. Stall Bucket, Curl In, for 15 seconds.
17. Stall Boom Down, for 15 seconds.
18. Stall Boom Up, for 15 seconds.
19. Stall Stick Out, for 15 seconds.
20. Stall Stick In, for 15 seconds.
21. Swing upper structure clockwise two complete revolutions. (Allow upper structure to stop
revolving)
22. Swing upper structure counter clockwise two complete revolutions. (Allow upper structure
to stop revolving)
23. Position boom over the RH track frame and lower the boom until the RH track is clear of the
ground.
24. Operate the RH track in the Forward direction for two complete revolutions then in the
Reverse direction for two complete revolutions. Lower the machine.
25. Position boom over the LH track frame and lower the boom until the LH track is clear of the
ground.
26. Operate the LH track in the Forward direction for two complete revolutions then in the
Reverse direction for two complete revolutions. Lower the machine.
27. Position the boom over the idlers lower the implements to the ground and select Throttle
Position 1. Idle engine for three minutes.
28. Lower the ladder to maintain the travel and swing brakes in the applied position.
29. Select Throttle Position 10.
30. Stall the RH Swing for 15 seconds.
31. Stall the LH Swing for 15 seconds.
32. Stall the RH Track in the Forward direction for 15 seconds.
33. Stall the RH Track in the Reverse direction for 15 seconds.
34. Stall the LH Track in the Forward direction for 15 seconds.
35. Stall the LH Track in the Reverse direction for 15 seconds.
36. Stall both tracks in the forward direction for 15 seconds.
37. Stall both tracks in the reverse direction for 15 seconds.
38. Select Throttle Position 1 and idle machine for 3 minutes.
39. Stop the Data Logger. Service program code: 3564 (DLOG)
40. Shut down the engine.
41. Down load the Data Logger file to a laptop computer.
42. Copy the downloaded file to three floppy discs. Supply one disc to the site maintenance
department, one disc to dealer and the other to LMP, Product Support Quality Supervisor.

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Swing Bearing Axial Clearance Check 5110B & 5130B

1. Determine that the swing bearing bolt torque turn procedure has been completed.
2. Install a dial indicator between the swing bearing inner ring and outer ring in order to measure vertical movement at
the lateral center and front (relative to the upper frame) of the swing bearing.
3. Raise the rear of the machine at the counter weight mounting until the rear of the carbody is clear of its support.
This will insure the zero clearance between the inner ring raceways, rollers and outer ring raceways at the front of
the machine.
4. Zero the dial indicator.
5. Raise the machine at the center pick points (This is done to insure the clearance reading is not influenced by the
swing drive pinions to swing gear mesh) until the carbody is totally clear of its support. This can be completed
without a crane by raising the rear of the machine by external jacks or using the linkage to tip the machine forward
and cribbing under the swing frame rails and then using the linkage as a jack to raise the front.
6. Read and record the dial indicator reading. This is the swing bearing axial clearance.
7. Record the following information

Machine Machine Swing Bearing Swing Bearing Swing Bearing Date of

Sales Model Serial Number Part Number Serial Number Axial Clearance Inspection

___________ _____________ _____________ ____________ _____________ _________

Bearing Hrs FS or ME Boom Length Stick Length Bkt Cap Manual or
At Check Auto Lube

________ _________ ___________ __________ _______ _________

Mtl Density Lube Type

_________ _________

8. Send to Steve Gill in Shovels Engineering, Mark Healy in Quality, and Bob Janssen in Product Support.

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