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Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any fitting, hose, or hydraulic component. Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly. 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. |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. |
| Specification | ||
| Function | Pressure | Actual |
| Standby Pressure | |
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| High Pressure Cutoff (HPCO) | |
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| Margin Pressure | |
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| Steering System Pressure (TPST) | |
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| Ejector System Pressure (TPH) | |
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This story includes the following tests:
- Piston Pump - Standby Pressure
- Piston Pump - High Pressure Cutoff
- Piston Pump - Margin Pressure
- Piston Pump - Case Drain Flow
- Steering System Pressure
- Ejector System Pressure
This story includes the following adjustment procedures:
- Adjustment Procedure (Piston Pump - High Pressure Cutoff)
- Adjustment Procedure (Piston Pump - Margin Pressure)
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| Illustration 1 | g02571852 |
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Tooling (A) 198-4240 Digital Pressure Indicator Gp | |
| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| A | 198-4240 | Digital Pressure Indicator Gp | ||
| A1 | 1 | 198-4234 | Digital Indicator | |
| A2 | 2 | 198-4239 | Pressure Sensor Gp
(0 to 41,368 kPa (0 to 6,000 psi)) |
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| A3 | 1 | 198-4236 | Adapter Cable As | |
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| Illustration 2 | g02726620 |
| Required Tools | ||||
|---|---|---|---|---|
| Tool | Item | Qty | Part No | Description |
| B1 | 1 | 8T-0856 | Pressure Gauge
(0 TO 6,000-KPA (0 TO 870-PSI)) |
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| B1 | 2 | 8T-0860 | Pressure Gauge
(0 TO 40,000-KPA (0 TO 5,800-PSI)) |
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| B2 | 1 | 6V-3989 | Fitting | |
| B3 | 2 | 6V-4143 | Quick Connect Coupler | |
| B4 | 1 | 177-7860 | Hose As
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| B4 | 1 | 177-7861 | Hose As
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| B4 | 1 | 177-7862 | Hose As
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| Illustration 3 | g06204033 |
| Tool | Item | Qty | Part Number | Description |
|---|---|---|---|---|
| C | 1U-5796 | Pressure Differential Tool Gp | ||
| C1 | 2 | 177-7861 | Hose As | |
| C2 | 4 | 6V-4143 | Quick Connect Coupler | |
| C3 | 3 | 6V-3965 | Fitting | |
| C4 | 1 | 6V-4144 | Quick Connect Coupler | |
| C5 | 2 | 8T-0860 | Pressure Gauge
(0 TO 40,000-KPA (0 TO 5,800-PSI)) |
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| C6 | 1 | 8C-8431 | Tee | |
| C7 | 1 | 1U-5793 | Oil Filter Pressure Differential Gauge Gp | |
| C8 | 1 | 6V-0484 | O-Ring Adapter | |
Note: Tooling (D) is to test the Margin Pressure. If a differential pressure gauge is not available, tooling (A) or tooling (B) may be used instead.
Note: You can view the discharge pressure of the implement pump through Advisor.
- Move the machine to a smooth, horizontal location that is away from operating machines and away from personnel.
- Permit only one operator on the machine. Keep all other personnel away from the machine or in the operator sight.
- Rotate the steering wheel to a NEUTRAL position.
- Move the transmission control to park to engage the parking brake.
- Lower or retract the implements.
- Move the ejector control to the float position.
- Stop the engine.
- Turn the key to the ON position, but do not start the engine.
- Verify that the implement controls are UNLOCKED.
- Move the control levers through the full range of travel several times. Moving the control levers should relieve any pressure that may be present in the implement hydraulic system.
- Install the steering frame lock. Refer to the Operation and Maintenance Manual, "Steering Frame Lock" for details.
Test Procedure - Standby Pressure (Piston Pump)
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| Illustration 4 | g06172190 |
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Test point location (1) Test Point Pump 2 Pressure (TP2) | |
- Perform Step 1 through Step 11 from the "Test Preparation" section.
- Attach tooling (A) or tooling (B) to TP2 pressure port (1).
- Operate the engine at low idle. Make sure that the steering wheel is in the neutral position.
- Place the ejector control lever in the hold position.
- Record the low pressure standby.
Note: Low-pressure standby occurs when the engine is running and the implement control levers are in HOLD position. Low-pressure standby is not adjustable. If low-pressure standby is not within the specified limit, perform the test procedure for margin pressure.
Test Procedure - High Pressure Cutoff (Piston Pump)
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| Illustration 5 | g06172190 |
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Test point location (1) Test Point Pump 2 Pressure (TP2) | |
- Perform Step 1 through Step 11 from the "Test Preparation" section.
- Attach tooling (A) or tooling (B) to TP2 pressure port (1).
- Operate the engine at high idle. Make sure that the steering wheel is in the neutral position.
- Move the ejector to the eject position. The pump will be at the stall condition once the cylinders reach the end of their stroke.
- Note the HPCO pressure. If the pressure is within the specified limit, the test is complete. If the pressure is not within the specified limit, perform the adjustment procedure in the"Adjustment Procedure - High Pressure Cutoff (Piston Pump)" section.
Adjustment Procedure - High Pressure Cutoff (Piston Pump)
- Ensure that the steering frame lock is installed. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
- Tilt the cab to access the piston pump and the pump control valve. Refer to Operation and Maintenance Manual, "Cab - Tilt".
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Illustration 6 g06189863 Steering and ejector pump location
(2) Piston Pump
(3) Pump Control Valve - Locate piston pump (2) and pump control valve (3) underneath the cab on the left side of the machine.
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Illustration 7 g06189879 (3) Pump control valve
(4) Cap nut
(5) Jam nut
(6) Adjustment screw - Remove cap nut (4) from pump control valve (3). This action will allow access to the adjustment screw.
- Loosen jam nut (5). Turn adjustment screw (6) clockwise to increase the system pressure. Turn the adjustment screw counterclockwise to decrease the system pressure.
Note: One turn of the adjustment screw will result in a pressure change of approximately
5500 kPa (800 psi) . - Return cap nut (4) to the original position.
- Lower the cab. Refer to Operation and Maintenance Manual, "Cab - Tilt".
- Perform the steps from "Test Procedure - High Pressure Cutoff (Piston Pump)" to determine if further adjustments are required.
- Repeat Step 4 through 8 Step until the HPCO matches the pressure provided in Table 1.
If the system pressure cannot be adjusted, there may be a problem with one of the components of the steering system or of the ejector system.
- Shut off the engine.
- Remove the pressure gauge from the machine.
- Remove the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
Test Procedure - Margin Pressure (Piston Pump)
- Perform Step 1 through Step 11 from the "Test Preparation" section.
Tilt the cab to access the steering/ejector piston pump and the main control valve. Refer to Operation and Maintenance Manual, "Cab - Tilt".
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Illustration 8 g06190189 (2) Piston Pump
(3) Pump Control Valve
(7) Pump Test Fitting - Install tooling (C) at test point (1) (TP2) on the main control manifold and at test fitting (7) on pump control valve (3). The pressure gauge must reach inside the cab.
Note: If a test fitting does not exist on the pump control valve, remove the steel plug and install a test fitting (P/N 110-6349) and dust cap (P/N 6V-0852).
- Lower the cab. Refer to Operation and Maintenance Manual, "Cab - Tilt".
- Navigate to "Braking System Charging Status" under "machine Status" menu in the Secondary Display.
Reference: Refer to Operation and Maintenance Manual , "Monitoring System" for instructions on how to access the "Brake System Charging Status" on the Secondary Display.
- Depress the brake pedal to full ON and release. Repeat until the “Brake System Charging Status” on the Secondary Display changes from “Not Charging” to “Charging”. Once the brake accumulators are charged (“Brake System Status” on the Secondary Display changes from “Charging” to “Not Charging”), do not depress the brake pedal during the margin test.
- Run the engine at high idle.
- Slowly place the ejector lever into the eject position to the point where the ejector blade begins movement and hold. Observe and record the pressure displayed on the differential pressure gauge while the blade is ejecting prior to hitting end of cylinder stroke. The pressure shown is the margin pressure. Lower the engine speed to low idle once the measurement of margin pressure has been recorded. Return the ejector blade to the fully retracted position.
Note: If you do not have a differential pressure gauge, then record the pressures from the two separate gauges. Subtract the recorded pressure at test fitting (7) from the recorded pressure at test point (1). The calculated pressure will be the margin pressure.
- Compare the pressure to the value provided in Table 1of the "Specifications" section. If the margin pressure is incorrect, the margin pressure must be adjusted.
Adjustment Procedure - Margin Pressure (Piston Pump)
- Shut off the engine and raise the cab to access the pump control valve which is part of the piston pump. Refer to Operation and Maintenance Manual, "Cab - Tilt" .
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Illustration 9 g06190216 (3) Pump control valve
(8) Cap nut
(9) Jam nut
(10) Adjustment screw - Remove cap nut (8) from pump control valve (3) and loosen jam nut (9).
- Turn adjustment screw (10) clockwise to increase the margin pressure. Turn adjustment screw (10) counterclockwise to decrease the margin pressure.
Note: One Turn of adjustment screw (10) will result in a pressure change of approximately
1400 kPa (200 psi) - Tighten jam nut (9) to a torque of
21 N·m (15 lb ft) . - Lower the cab. Refer to Operation and Maintenance Manual, "Cab - Tilt".
- Repeat the procedure from step 4 until the margin pressure is correct.
- Perform the steps from "Test Procedure - Margin Pressure (Piston Pump)" to determine if further adjustments are required.
- Repeat Step 2 through Step 8 until the margin pressure matches the pressure provided in Table 1.
If the system pressure cannot be adjusted, there may be a problem with one of the components of the steering system or of the ejector system.
- Shut off the engine and remove the pressure gauge from the machine.
Test Procedure - Steering System Pressure
- Perform Step 1 through Step 11 from the "Test Preparation" section.
- Install the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
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Illustration 10 g06190470 Test point location
(11) Test Point Steering System (TPST) - Attach tooling (A) or tooling (B) to TPST (11).
- Start the engine and run the engine at low idle.
- Articulate the machine fully to the left and then record the reading on the pressure gauge.
- Articulate the machine fully to the right and then record the reading on the pressure gauge. The pressure shown is the maximum pump pressure for the steering system.
- Compare the pressure to the value provided in Table 1of the "Specifications" section.
- If the steering system pressure is correct, shut off the engine and remove the test equipment and the steering frame locks from the machine. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
Note: If the steering system pressure is incorrect, the piston pump pressure should be tested. Refer to "Test Procedure - High Pressure Cutoff (Piston Pump)".
Test Procedure - Ejector System Pressure
- Perform Step 1 through Step 11 from the "Test Preparation" section.
Install the steering frame lock. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
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Illustration 11 g06190492 Test point location
(12) Test Point Ejector System (TPH) - Attach tooling (A) or tooling (B) to TPH (12).
- Start the engine and run the engine at high idle
- Move the ejector control to the eject position. When the ejector blade is fully extended, hold the ejector control in the eject position and record the pressure that is displayed on the pressure gauge. The pressure shown is the maximum ejector pressure at high idle.
- Compare the pressure to the value provided in Table 1of the "Specifications" section.
- If the ejector system pressure is correct, shut off the engine and remove the test equipment and the steering frame locks from the machine. Refer to Operation and Maintenance Manual, "Steering Frame Lock".
Note: If the ejector system pressure is incorrect, the piston pump pressure should be tested. Refer to "Test Procedure - High Pressure Cutoff (Piston Pump)".
Test Procedure - Case Drain (Piston Pump)
- Perform Step 1 through Step 11 from the "Test Preparation" section.
- Remove the filler cap from the hydraulic tank for the steering and the ejector systems. This action will relieve the pressure from the hydraulic tank.
- Tilt the cab to access the piston pump. Refer to Operation and Maintenance Manual, "Cab - Tilt".
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Illustration 12 g03777041 - Disconnect hose (A) from fitting (B). Install a 6V-9511 Plug into hose (A). Remove fitting (B) from piston pump (9).
- Install a 9U-6997 Elbow into piston pump (8). Use a 9M-7958 Hose Clamp to connect a 5P-2094 Hose that is approximately
3 m (10 ft) long. - Place the end of the 5P-2094 Hose into a suitable container that has a minimum capacity of
35 L (9.2 US gal) . - Lower the cab. Refer to Operation and Maintenance Manual, "Cab - Tilt".
- Start the engine.
Run the engine at low idle and move the ejector control to the eject position. When the ejector blade is fully extended, shut off the engine and remove the hose from the container.
Place the end of the hose into a second suitable container that has a minimum capacity of
35 L (9.2 US gal) .Start the engine. Run the engine at high idle and hold the ejector control in the eject position for 30 seconds.
Shut off the engine.
Place the end of the hose into a first container.
Start the engine and retract the ejector blade.
- Measure the amount of oil that has been collected in the second container. This collection is the case drain oil.
If the amount of oil collected in the container less than
15 L (4 US gal) proceed to Step 11.If the amount of oil that is collected in the container exceeds
15 L (4 US gal) , remove the piston pump from the machine. - Remove the hose clamp, the hose, and the elbow from piston pump (9) and install tee (B)
- Install fitting (B) into piston pump (9). Remove the plug from hose (A) before connecting the hose to fitting ().
