CHAPTER : Lab Exercises

LAB B WORK SHEET

SYSTEM PROCEDURES (324D) SPECS ACTUAL

POWER SHIFT FL RPM

PRESSURE 1800
- QUICK TEST - CONNECTOR (324D)
SYSTEM
PRESS.
ENGINE PERFORMANCE 2 PUMPS 17845/
PRESSURE 18845 kPa
TEST
BOOST
(as a ref. only)

Test Preparation : ENGINE PERFORMANCE CHART

FL SYS. PRESS. Max Flow 2 P
Oil temp. 55 MODEL RPM HP (PS disconnec) (at 0 sys press.)
Dial : 10
Connect a gauge to the pump delivery 320D 1800 138 13800 410 +/-6L
pressure tap
Screw counterclockwise by tree turns 323D 1800 139 13800 410 +/-6L
the Main Relief Valve
MESSAGE 324D 1800 188 18345 440 +/-6L
Disconnect the PS pressure solenoid
Activate the Main Menu - Performance - CENTER
MAIN 325D 1800 197 17000 470 +/-6L
ENG SPEED RELIEF
Slowly actuate "Stick in" and hold the VALVE 330D 1800 261 18900 560 +/-6L
joys tick in this position.
Observe the Eng. rpm on Center Display
while turning clockwise the Main Relief
Valve, when the Eng. rpm decrease
to the Full load rpm. the system press.
should be between 17845 and 18845 kPa

KEYPAD
Tool Required :
Wrenches: 24 and 27

OK

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 CHAPTER : Lab Exercises

LAB C WORK SHEET

SYSTEM PROCEDURES (324D) SPECS (kPa) ACTUAL

60000 kPa ACTUATOR

Pressure Tetra
- QUICK TEST - Gauche Gauche Start to Decr.
RIGHT
MAIN PUMP DIS. PRESS.
16800+/-500
DE STROKING PRESSURE
(Reference Point) DRIVE MAIN HYD.PUMP ACTUATOR
DRIVE PUMP Start to Decr.
PRESS. TAP
LEFT
Test Preparation : DIS. PRESS.
Oil temp. 55 16800+/-500
Dial : 5
Screw counterclockwise by tree turns DE STROKING PRESSURE CHART
the Main Relief Valve HORSEPOWER
Connect a gauge to the pump delivery ADJ SCREW
SYS. PRESS. PS PRESS. ACTUATOR
pressure tap of the pump been tested MODEL (required) PRESS.
(required)
Connect a gauge to the Power Shift 6000 kPa start to
pressure tap Pressure
320D 12240 1300 decrease
Connect a tetra gauge to the actuator Gauche start to
323D 12240 1300 decrease
pressure tap of the pump been tested ACTUATOR
From the monitor, activate the Main Menu - PRESS. TAP start to
324D 16800 1300 decrease
Service - Devise Test - and select Power
start to
Shift Pres IDLE MAIN HYD.PUMP 325D 16900 1300 decrease
Input a power shift press. of 1300 kPa at the
start to
power shift pressure gauge. 330D 15700 1620 increase (500/600)
Slowly actuate "Stick in" and hold the
joys tick in this position.
MESSAGE
Observe the actuator press. gauge while CENTER
turning clockwise the Main Relief Valve,
when actuator press. begins to decrease
the Pump delivery press. should be MAIN
between 16200 and 17200 kPa. RELIEF KEYPAD
VALVE

Tools Required :
Wrench ? + ? (Power Adj. Screw)
Wrenches 24 and 27 (Main Relief Valve) POWER SHIFT OK
PRESS. TAP

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 CHAPTER : Lab Exercises

LAB D WORK SHEET

SYSTEM PROCEDURES (330D) SPECS (kPa) ACTUAL

Tetra ACTUATOR
ACTUATOR Gauge
- QUICK TEST - Pressure HORSEPOWER
PRESS. TAP Start to Incr
Gauge ADJ SCREW Cover Block
(60000 kPa) RIGHT
MAIN PUMP DIS. PRESS.
15700+/-500
DE STROKING PRESSURE
(Reference Point) ACTUATOR
Start to Incr
LEFT
Test Preparation : DIS. PRESS.
Oil temp. 55 15700+/-500
Dial : 5
Install fabricated cover block
DE STROKING PRESSURE CHART
Screw counterclockwise by tree turns
the Main Relief Valve
SYS. PRESS. PS PRESS. ACTUATOR
Connect a gauge to the pump delivery MODEL (required)
345C (required) PRESS.
pressure tap of the pump been tested
start to
Connect a gauge to the Power Shift 320D 12240 1300 decrease
pressure tap start to
Connect a tetra gauge to the actuator 323D 12240 1300 decrease
pressure tap of the pump been tested Pressure start to
DRIVE PUMP 324D 16800 1300
Gauge decrease
From the monitor, activate the Main Menu - PRESS. TAP (6000 kPa) start to
Service - Devise Test - and select Power 325D 16900 1300 decrease
Shift Pres
start to
Input a power shift press. of 1620 kPa at the 330D 15700 1620 increase (?)
power shift pressure gauge.
Slowly actuate "Stick in" and hold the
joys tick in this position. MESSAGE
MAIN CENTER
Observe the actuator press. gauge while RELIEF
turning clockwise the Main Relief Valve, VALVE
when actuator press. begins to increase
the Pump delivery press. should be KEYPAD
between 15200 and 16200 kPa.
Tools Required : 345C

Wrench ? + ? (Power Adj. Screw)

Wrenches 24 and 27 (Main Relief Valve) POWER SHIFT
PRESS. TAP OK

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 CHAPTER : Lab Exercises

LAB E WORK SHEET

PRESSURE SPECIFICATIONS

One Turn of Adjustment

RELIEF VALVE MODEL SPECS ACTUAL Screw will change: TOOLS REQUIRED

Main Relief Valve

320D/330D 35000 +/- 500 14400 kPa
Implement & Travel
Heavy Lift 320D/330D 36000 +/- 500
Line Relief Valves
320D/330D 38000 +/- 500 11000 kPa
Implements
320D/
26000 +/- 500
323D
Swing Relief Valves 324D/ 6800 kPa
29400 +/- 500
325D
330D 30400 to 32400
320D
323D
37500 +/- 500
Travel Crossover Relief Valves 324D 3050 kPa
325D
330D 36300 to 38300
Pilot Relief Valve 320/330D 4100 +/- 200 620 kPa
Std Max 1140 +- 30, Min 800 +- 30 rpm A quarter turn
OIL COOLER SYSTEM 330D
H Am Max 1360 +- 30, Min 900 +- 30 rpm will change : 3300 kPa
AUXILIARY CIRCUIT (Stem 3)
Main Relief Valve 20600 +/- 500
Line Relief Valve 22600 +/- 500
CYLINDER OPER. SPEED +/-0.5 320D 323D 324D 325D 330D
Extension 2.8 2.8 3.1 3.5 3.8
Boom
Retraction 1.9 1.9 2.4 2.4 2.6 Check the machine
configuration to achieve
Extension 3.4 3.4 3.1 3.0 3.4 these specifications
Stick
Retraction 2.5 2.5 2.7 2.6 2.8
Extension 3.5 3.5 3.9 3.9 4.4
Bucket
Retraction 1.9 1.9 2.1 2.3 2.5

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 CHAPTER : Lab Exercises

LAB F WORK SHEET 1

BOOM UP
BOOM AND SWING PRIORITY PRESSURE REDUCING VALVES
PILOT PRESSURE ADJUSTMENT PROCEDURES
SWING PILOT
PRESSURE
6000 kPa
Press. Gauge
6000 kPa
Press. Gauge

STICK IN B1 PILOT SYSTEM

PILOT PRESSURE PRESSURE
B2

6000 kPa 6000 kPa

Press. Gauge Press. Gauge

P1 P2

A1
TO STICK II
A1 A2
STICK IN TO SWING
PILOT PRESSURE MODULATION
VALVE

BOOM PRIORITY SWING PRIORITY

PRESSURE REDUCING PRESSURE REDUCING
VALVE VALVE

BOOM PRIORITY SWING PRIORITY

BOOM PRIORITY PRESSURE REDUCING VALVE
ADJUSTMENT SCREW ADJUSTMENT SCREW
1. Install (6000 kPa) pressure gauges in lines B1 and A1.
2. Disconnect swing parking brake solenoid.
SWING PRIORITY PRESSURE REDUCING VALVE
3. Start engine and warm the hydraulic oil to 50 C
4. Place engine speed dial in position "10".
1. Install (6000 kPa) pressure gauges in lines B2 and A2.
5. Actuate the Boom up and Stick in pilot controls to full stroke.
2. Disconnect swing parking brake solenoid.
6. Modulate the Boom up pilot control until pressure in B1 gauge reads 1960 kPa.
3. Start engine and warm the hydraulic oil to 50 C
7. At the same time read the pressure at A1. Should be 1960 +/-100 kPa
4. Place engine speed dial in position "10".
5. Modulate the Swing pilot control until pressure in B2 gauge reads 1960 kPa.
6. At the same time read the pressure at A2. Should be1960 +/-100 kPa

Service Training Malaga 11

 CHAPTER : Lab Exercises

LAB F WORK SHEET 2

BOOM AND SWING PRIORITY PRESSURE REDUCING VALVES

PRESSURE TEST PORT LOCATION

PRESSURE TEST PORT

SWING (B2)

PRESSURE TEST PORT PRESSURE TEST PORT

STICK IN II (A1) BOOM UP (B1) PRESSURE TEST PORT
SWING MODULATION VALVE (A2)
BOOM PRIORITY PRESSURE REDUCING VALVE TEST PORT

SWING PRIORITY PRESSURE REDUCING VALVE TEST PORT

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 CHAPTER : Lab Exercises

LAB G WORK SHEET

STICK OUT AND BUCKET CLOSE PRIORITY PRESSURE
REDUCING VALVES ADJUSTMENT PROCEDURES (325-330D ONLY)

From Stick out

6000 kPa
Pilot Joystick
Pressure
Gauche To Stick out
Control Spool
From Bkt close
Pilot Joystick

B2
B2 B1 B1

P2
6000 kPa
P1

A1 A2 A2

6000 kPa
Pressure
Gauche

A1
BUCKET CLOSE STICK OUT
PRESS. REDUC. PRESS. REDUC.
VALVE VALVE

A1
2500 +/- 50 kPa
To Bkt close
Press. Reduc. Valve
Control Spool

STICK OUT PRIORITY PRESSURE REDUCING VALVE BUCKET CLOSE PRIORITY PRESSURE REDUCING VALVE

1. Install a (6000 kPa) pressure gauge in lines B1 or B2.
2. Disconnect swing parking brake solenoid.
3. Start engine and warm the hydraulic oil to 50 C
4. Place engine speed dial in position "10".
5. Actuate the Boom up and Stick out pilot controls to full stroke.
6. Modulate the Boom up pilot control until pressure at B1 or B2 gauge reads 1960 kPa.
7. At the same time read the pressure at A2. Should be 1960 +/-100 kPa
1. Install a (6000 kPa) pressure gauge in lines B1 or B2 and A1
2. Disconnect swing parking brake solenoid.
3. Start engine and warm the hydraulic oil to 50 C
4. Place engine speed dial in position "10".
5. Actuate the Boom up and Bucket close pilot controls to full stroke.
5. Modulate the Boom up pilot control until pressure at B1 or B2 gauge reads 1960 kPa.
6. At the same time read the pressure at A1. Should be1960 +/-100 kPa

Service Training Malaga 13

 CHAPTER : Lab Exercises

LAB H WORK SHEET

MAIN MENU SCREEN
OUT LINE OF DISPLAY SETUP

MAIN MENU
SETTING

SETTING DISPLAY SETUP DISPLAY SETUP

MAINTENANCE INFO WORK TOOL SELECT CLOCK ADJUST

CLOCK ADJUST
PERFORMANCE LANGUAGE SELECT LANGUAGE SELECT
HH:MM
SERVICE MAINTENANCE INFO INDICATED ITEM
ENGLISH
CONTRAST
MAINTENANCE ENGINE OIL FILTER
BRIGHTNESS FRANCAIS
You can reset accumulated XXXX/YYYY (HR)
hour of filters and fluids and HYD OIL RET FILTER BRIGHTNESS ( ) DEUTSCH
work hour of components, XXXX/YYYY (HR)
and change recommended
ITALIANO
intervals. You can also A list of system components
ENTER PASSWORD will be displayed
operate Reversing Fan WORK TOOL SELECT
System. ESPANOL
Enter User Password or
Service Password TOOL #1
OTHERS
PASSWORD CHANGE TOOL #2
PERFORMANCE TOOL #3
You can change user
SERVICE password TOOL #4
BATTERY VOLTAGE INDICATED ITEM
_ _ _ _ (HR) OTHERS
MAINTENANCE DIAGNOSTIC
ENGINE SPEED TOOL NAME
PASSWORD CHANGE You can check diagnostic _ _ _ _ (RPM) SERVICE HR METER
DIAGNOSTIC information (real time error,
logged error, logged events) A list of system components ECONO MODE FIX
ECM INFO and measurements will be
displayed
STATUS ECM INFO

CALIBRATION You can see each ECM

information
DEVICE TEST Password Entry CONTRAST
OVERRIDE STATUS
Brightness Screen
CONFIGURATION You can see inputs of
sensors and switches
TOOL PROGRAM Brightness ( ) Screen
outputs of machine ECM
5
CALIBRATION
You can calibrate each device

DEVICE TEST

You can test each device

OVERRIDE

You can test each device OK

CONFIGURATION OK
You can configure machine
ECM OK
TOOL PROGRAM

You can program each tool

setting
OK

Service Training Malaga 14