Global Service Learning: 300D Series Hydraulic Excavators - Tier Iii Engines

SERV1852-02
September 2011
GLOBAL SERVICE LEARNING
INSTRUCTOR MATERIALS
300D SERIES HYDRAULIC

EXCAVATORS - TIER III ENGINES
(INCLUDES 320D-336D)
Service Training Meeting Guide

(STMG)
SERV1852-02 -2- Student Materials
09/11
MODULE OBJECTIVES
After completion of this module, the student will be able to:

1. Given a machine locate and identify during lab exercises:
A. the pilot system components using Lab A Worksheets.
B. the implement pumps and pump components using Lab C
Worksheets.
C. the main control valve, main relief valve and other components
using Lab E Worksheets.
D. the cylinders, travel system, final drives and swivel using Lab G
Worksheets.
E. the swing system components using Lab I Worksheets.
F. the return system components during a lab exercise using Lab K
Worksheets.
2. Given a machine and the appropriate service literature perform the

following tests during a lab exercises. All pressures and flows must
be within the Service Manual Specifications:
A. Test and adjust the pilot system relief valve using Lab B
Worksheet.
B. Test and adjust the travel/implement pump constant horsepower
controls and test and adjust the implement/travel pump negative
flow controls using Lab D Worksheets.
C. Test and adjust the implement line relief valves and test and
adjust the main relief valve using Lab F Worksheets.
D. Test and adjust the travel crossover relief valves and measure
the travel motor case drain flow using Lab H Worksheets.
E. Test and adjust the swing system relief valves, measure the
swing motor case drain flow, and test the swing brake solenoid
valve using Lab J Worksheets.
09/11
MODULE OBJECTIVES (continued)
3. Given all reference material and class notes:

A. Correctly identify potential system problems caused by an
improperly operating hydraulic system during a case study.
4. Given all reference material and class notes, on a posttest:

A. Correctly answer true or false statements regarding hydraulic
system operation.
B. Correctly fill in the blanks regarding hydraulic system pressures.
C. Correctly match the function to the corresponding hydraulic
system component
09/11
Lab A: Locate and Identify Pilot System Components
BACKGROUND This lab will allow you to gain "hands on" experience locating and
INFORMATION identifying the pilot system components. In addition, you will be use the
parts manual or SIS to identify the correct Caterpillar part name and part
number.
MATERIALS NEEDED Lab A Worksheets

A 320D-336D Hydraulic Excavator
Appropriate Parts Manual (or SIS)
INDIVIDUAL OR GROUP During the presentation, use the "Lab A: Locate and Identify Pilot
EXERCISE System Components," Worksheets to record the location and function of
the components.
Then, use the parts manual, or SIS, to correctly fill in the appropriate part
name and number of each component.
Fill in the blank statements regarding component location and function.
In the lab, locate and identify the components on the machine, and record
your results on the Lab A Worksheets.
Review results with your instructor.

09/11
Lab A Worksheet 1
Locate and Identify Pilot System Components
Directions: During the presentation, use these worksheets to take notes as the function of each
component is explained. Use the parts book and the hydraulic schematic to fill in the required
information. Place a check in the blank next to the component after locating the component on the
machine.
Example: 9 Pilot Pump

Location: The single section gear pump mounted on the right main implement pump.
Function: Supplies pilot system oil flow to the pilot filter, pilot manifold and pilot systems.
Parts Manual Part Name: Pump Gp - Gear Part No.: 186-6423
Pilot Filter
Location: On the rear of the hydraulic tank at the front of the pump compartment.
Function: Filters oil before pilot oil goes to any of the pilot systems.
Parts Manual Part Name: Part No.:
Pilot System Pressure Test Port

Location: Quick disconnect nipple located on the side of the pilot oil filter base.
Function: For measuring the pilot system pressure.
Pilot Manifold
Location: On the inside left of the swing frame below the .
Function: A manifold block containing the travel speed solenoid, the swing brake release solenoid,
the hydraulic activation solenoid, and the .
Distributes pilot system oil to various systems on the machine.

09/11
Lab A Worksheet 2
Pilot System Pressure Relief Valve

Location: On the base of the oil filter.
Function: Limits the pilot system pressure.
Pilot System Accumulator

Location: On the inside of the swing frame below the main control valve.
Function: Provides stored energy to the pilot system. The pilot system accumulator dampens pressure
spikes in the pilot system during normal operation. Also, allows the operator to lower the
implements when the engine is shut down.
Swing Parking Brake Solenoid Valve

Location: The second solenoid from the of the pilot manifold.
Function: When energized by the Engine/Pump Control Module, the solenoid sends pilot system oil to
_________ the swing brakes.
Hydraulic Actuation Control Valve

Location: Only valve on the Pilot Oil Manifold that is not directly controlled by a .
Function: When actuated by the , this control valve
directs pilot oil to the joysticks and the remainder of the pilot system to enable activation
and control of the machine's hydraulic functions.
09/11
Lab A Worksheet 3
Hydraulic Actuation Solenoid Valve

Location: On the of the pilot manifold.
Function: When actuated by the , this solenoid
valve directs pilot system oil to actuate the Hydraulic Actuation Control Valve.
Hydraulic Actuation Lever

Location: On the left operator console.
Function: Opens and closes the hydraulic actuation microswitch. When the hydraulic actuation
micro switch is closed, an electronic signal is sent to the .
Power Shift Solenoid Valve

Location: The side of the right main implement pump.
Function: It receives a signal from the Engine/Pump Control Module, based upon engine
speed, engine speed dial position, and pump output pressures. The Power shift PRV then
sends modulated pilot system pressure to the implement pump control valves to assist in
regulating implement pump flow.
Pilot Pressure Release Line for Swing Parking Brakes

Location: The pilot pressure line going to the swing brake on the of the swing motor.
Function: Provides pilot system oil to the swing brake solenoid for releasing the swing brake. The
swing brakes are applied and released by .

09/11
Lab A Worksheet 4
Two Speed Travel Solenoid Valve

Location: The top solenoid valve mounted on the .
Function: When this solenoid valve is actuated by the Engine/Pump Control Module, pilot system
pressure is sent to the speed change valves in the travel motors. When the speed change
valves are actuated, the travel motor swashplates are set at the angle for
fast travel speed.
Implement/Swing Resolver Valve

Location: On the bottom of the . Located inside the belly pan
compartment from the front of the machine, under the .
Function: Ensures that the highest joystick signal pressure, regardless of function, is directed to
the .
Swing/Boom Priority Valves

Location: Located under the , behind the swing bearing, on the right
hand side of the frame for the upper structure.
Function: Allows the operator to adjust hydraulic flow priority to the swing or boom circuits,
depending SOLELY on the movement of the .
Left Travel Pressure Switch

Location: On the left side of the travel pilot control valve beneath the operator station.
Function: Signals the Machine ECM that the is activated.

09/11
Lab A Worksheet 5
Implement/Swing Pressure Switch (AEC)

Location: On the Implement/Swing Resolver Valve.
Function: Signals the Machine ECM that the implement or swing functions have been activated.
Straight Travel Pressure Switch

Location: On the straight travel control valve beneath the .
Function: Signals the Machine ECM that the straight travel function is activated.
Right Travel Pressure Switch

Location: On the side of the travel control valve beneath the operator station.
Function: Signals the Machine ECM that the right travel pedal is activated.
Pilot System S•O•S Fitting

Location: On the top side of the pilot filter base, as viewed from outside the pump
compartment.
Function: Allows the technicians to obtain S•O•S samples from the hydraulic system.

SERV1852-02 - 10 - Student Materials
09/11
Lab B: Test and Adjust Pilot System Relief Valve
BACKGROUND
This lab measures your ability to perform the testing and adjusting
INFORMATION
procedure for the pilot system relief valve.
MATERIALS NEEDED Lab B Worksheets

320D-336D Excavator Hydraulic System Operation
Testing and Adjusting
1 - 8T0856 Gauge [6000 kPa (870 psi)]
INDIVIDUAL OR GROUP Enter the correct specifications from the service manual module on the
EXERCISE lab worksheet.
Using the procedures in the service manual, run the correct test
procedure. Adjust as needed. Record your results in the space provided.
Review your results with the instructor.
09/11
Lab B Worksheet
Test and Adjust Pilot System Relief Valve
Machine Model Date
Serial Number Service Meter Hours
Tooling for Pilot Relief Valve Test
1 - 8T0856 Gauge [6000 kPa (870 psi)]
NOTE: For the complete procedures to test and adjust the pilot system relief valve, refer to a
Testing and Adjusting Service Manual module for a 320D-336D hydraulic excavator.
Item Specification Actual

Pilot relief valve
NOTE: Test the pilot relief valve pressure with the engine speed dial at Position
10. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
09/11
Lab C: Locate and Identify Implement/Travel Pumps and

Pump Components
identifying the pilot system components. In addition, you will be use the
INFORMATION
number.
Lab C Worksheets
MATERIALS NEEDED
INDIVIDUAL OR GROUP During the presentation, use the "Lab C: Locate and Identify
EXERCISE Implement/Travel Pumps and Pump Components," Worksheets to record
the location and function of the components.
In the lab, locate and identify the components on the machine and record
your results on the Lab C Worksheets.

09/11
Lab C Worksheet 1
Locate and Identify Implement/Travel Pumps and Pump Components
information. Place the correct letter or number from the machine next to the listed component.
Some of the responses below reflect the 320D-329D machines only and may not be correct for the
330D-336D machines.

Implement/Travel Pump Group

Location: In pump compartment on center of flywheel housing/pump drive.
Function: Supplies to the main control valve group.
Drive Pump
Location: The drive pump is driven by the .
Function: Supplies oil to the half of the main control valve group.
Idler Pump
Location: The idler pump is driven by the .
Function: Supplies oil to the half of the main control valve group.

09/11
Lab C Worksheet 2
Suction Line
Location: The single line connected to bottom center of the implement/travel pump.
Function: The supply line from the hydraulic tank to the .
Pump Case Drain Line

Location: Connected to top of the pump
Function: A line sending internal leakage oil from the front pump back to the hydraulic tank.
Maximum Angle Adjustment

Location: On the the drive implement pump of the horsepower adjustment. On
the of the idler implement pump the horsepower adjustment.
Function: Changes the pump swashplate maximum angle stop to set .
Minimum Angle Adjustment

Location: On the of the drive implement pump of the horsepower adjustment. On
the of the idler implement pump the horsepower adjustment.
Function: Changes the pump swashplate minimum angle stop to set .
Machine ECM
Location: The Machine ECM in the compartment .
Function: Controls the implement/travel pump power shift solenoid. Monitors the implement/travel
pump system pressure sensor.

09/11
Lab C Worksheet 3
Implement/Travel Pump Control Valve Group

Location: Mounted on the of each pump.
Function: Regulates pump output oil flow based on the pressures it receives.
Negative Flow Control (NFC) Signal Pressure Port

Location: On the of the drive pump. On the of idler pump.
Function: Receives a signal from the main control valve group.
Power Shift Signal Pressure Port

Location: On the of the pump.
Function: Receives the power shift pressure signal from the _ .
Horsepower Control Pressure Adjustment

Location: On front of each pump control valve.
Function: Regulates the pump discharge pressure point on the constant horsepower curve where the
pump control valve begins to the pump.
Implement/Travel Pump Pressure Sensors

Location: The pressure sensors on the front of .
Function: Signal the Machine ECM with the pressure being produced in the
systems.

09/11
Lab D: Test and Adjust Implement/Travel Pumps
BACKGROUND This lab measures your ability to perform the testing and adjusting
INFORMATION procedures for the main implement/travel pumps.
MATERIALS NEEDED Mechanic’s Tool Box and hand tools
Appropriate Service Manual modules
Lab D Worksheets
Refer to each Test Worksheet for the tooling required.
EXERCISE
lab worksheet, including the measuring points before going to the shop.
09/11
Lab D Worksheet 1
Test and Adjust Implement/Travel Pump Constant Horsepower Control
Machine Model Date
Constant Horsepower Control Test Tooling:

1 - 8T0856 Gauge [6000 kPa (870 psi)]
1 - 8T0861 Gauge [60000 kPa (8700 psi)]
1 - 4C9910 Portable Hydraulic Tester (flow meter)
1 - 6V9840 Swivel Tee
1 - 9U7335 Blocking Cover
1 - 1U8303 Fitting
1 - 5K9090 O-ring seal
1 - 5P0201 Hose
1 - 5P1010 Sleeve
1 - 4C8767 Coupling
1 - 7M8485 O-ring seal
1 - 4C6481 Coupler Assembly
1 - 4C6482 Nipple Assembly
1 - 4I6141 Coupling
1 - 8C9026 Adapter
1 - 6V9854 Swivel elbow
1 - 1P3703 Rectangular seal
1 - 8T4184 Bolt
1 - 8T4223 Hard washer
1 - 6V0400 Half flange
1 - 1U8292 Adapter
testing and adjusting Service Manual module for a 320D-336D hydraulic excavator.
09/11
Lab D Worksheet 2
Test and Adjust Implement/Travel Pump Constant Horsepower Control
320D-336D IMPLEMENT/TRAVEL PUMP P-Q CURVE

200
150
FLOW (L/min)
100
50
5 10 15 20 25 30
PRESSURE (kPa x 1000)
PUMP FLOW TEST

Measuring Points
Measured Flow liter/min Drive Pump

(US gpm) Idler Pump
Drive Pump
Idler Pump
Drive Pump
Engine Speed (rpm)
Idler Pump
Corrected Flow L/min Drive Pump
(US gpm) Idler Pump
Spec. Flow L/min New
(US gpm)
Service
Limit
FORMULA FOR PUMP FLOW CORRECTION

Measured Flow x 1800 rpm
Corrected Flow =
Measured rpm
09/11
Lab D Worksheet 3
Test and Adjust Implement/Travel Pump Negative Flow Control
Machine Model Date
Destroking Pressure Test Tooling:
1 - 8T0856 Gauge [6000 kPa (870 psi)] 1 - 8T4223 Hard washer

1 - 8T0861 Gauge [60000 kPa (8700 psi)] 1 - 6V0400 Half flange
1 - 4C9910 Flow meter 1 - 1U8292 Adapter
1 - 6V9840 Swivel Tee
1 - 9U7335 Blocking Cover
1 - 1U8303 Fitting
1 - 5P0201 Hose
1 - 5P1010 Sleeve
1 - 4C8767 Coupling
1 - 7M8485 O-ring seal
1 - 4C6481 Coupler Assembly
1 - 4C6482 Nipple Assembly
1 - 4I6141 Coupling
1 - 8C9026 Adapter
1 - 6V9854 Swivel elbow
1 - 1P3703 Rectangular Seal
1 - 8T4184 Bolt
Pump Specification Actual

Left
Right
09/11
Lab E: Locate and Identify the Main Control Valve and

Main Control Valve Components
number.
MATERIALS NEEDED Lab E Worksheets

INDIVIDUAL OR GROUP During the presentation, use the "Lab E: Locate and Identify the Main
EXERCISE Control Valve and Main Control Valve Components," Worksheets to
record the location and function of the components.
your results on the Lab E Worksheets.

09/11
Lab E Worksheet 1
Locate and Identify the Main Control Valve and Main Control Valve Components

Implement Control Valve Group

Location: Between the swing frame rails in front of the engine.
Function: Controls the boom, stick, bucket, travel and attachment functions and contains the relief
valves.
Boom I Spool
Location: (Refer to Lab E Handout 1).
Function: Controls oil flow from the pump to the boom function.
Boom II Spool
Function: Controls oil flow from the pump to the boom function.
Bucket Spool
Function: Controls the bucket curl function.
Standard Attachment Spool (AUX Stem 1)

Function: Directs oil to an attachment circuit, if the machine is equipped.
09/11
Lab E Worksheet 2
Straight Travel Spool

Function: Directs the right and left pump oil flow. Allows the machine to travel in a straight line
when travel and implement functions are used simultaneously.
Stick I Spool
Function: Controls oil flow from the left pump to the stick function.
Stick II Spool
Function: Controls oil flow from the right pump to the stick function.
Left Travel Spool

Function: Directs oil to the left travel motor.
Right Travel Spool

Function: Directs oil to the right travel motor.
Load Check Valve

Function: The load check function prevents an implement from until pump discharge
pressure is than work port pressure.
09/11
Lab E Worksheet 3
Boom Regeneration Valve

Function: Used to "recycle" oil from the of the boom cylinders to the of the
cylinders during the BOOM LOWER operation. This improves system response,
controllability, and efficiency.
Boom Drift Reduction Valve

Location: On lower front of boom spool on main control valve, just above the pilot accumulator.
Function: Prevents boom cylinders from due to leakage through the boom spool.
Stick Drift Reduction Valve

Location: On lower front of stick spool on main control valve.
Function: Prevents stick cylinder from drifting in due to through the stick spool.
Machine ECM
Location: The ECM in the compartment behind the cab.
Function: The ECM controls the machine monitoring system and controls the functions.
Stick Regeneration Control Valve

Function: Directs oil from the of the stick cylinder to the during the STICK IN
operation.
Swing Control Valve

Function: Controls the swing function.

09/11
Lab E Handout 1
B
A
B
N
MAIN CONTROL VALVE
M
A
B
J
I
H
G
F
E
D
C
B
A
A
B
K
L
09/11
Lab F: Test and Adjust Implement Line Relief Valves and

Main Relief Valve
INFORMATION procedures for the line and main reliefs.
Lab F Worksheets
Appropriate Hydraulic System Schematic (or SIS)
09/11
Lab F Worksheet 1
Test and Adjust Implement Line Relief Valves
Machine Model Date
Line Relief Valve Pressure Tooling:

1 - 8T0861 Gauge
1 - 8T0856 Gauge
Function Specification Actual

Boom raise ____________________ ____________________
Boom lower ____________________ ____________________
Stick in ____________________ ____________________
Stick out ____________________ ____________________
Bucket open ____________________ ____________________
Bucket close ____________________ ____________________
Attachment, front line relief ____________________ ____________________
Attachment, rear line relief ____________________ ____________________
NOTE: Test the line relief valve pressures with the engine speed dial in Position
2. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
09/11
Lab F Worksheet 2
Test and Adjust Main Relief Valve
Machine Model Date
Line Relief Valve Pressure Tooling:

1 - 8T0861 Gauge
Main relief valve ____________________ ____________________

09/11
Lab G: Locate and Identify Travel System, Final Drive and

Swivel Components
number.
Lab G Worksheets
MATERIALS NEEDED
INDIVIDUAL OR GROUP During the presentation, use the "Lab G: Travel System, Final Drive, and
EXERCISE Swivel Components," Worksheets to record the location and function of
the components.
your results on the Lab G Worksheets.

09/11
Lab G Worksheet 1
Locate and Identify Travel System Components

Left Travel Spool

Location: The inside spool in the left half of the implement control valve.
Function: Directs oil to the left travel motor.
Right Travel Spool

Location: The inside spool in the right half of the implement control valve.
Function: Directs oil to the right travel motor.
Travel Counterbalance Valves

Location: Mounted vertically on the left and right travel motors.
Function: Provide passages for pump flow to the travel motor and return flow from the travel motor
to the tank. In addition, the counterbalance valve contains a passage that releases the
travel parking brakes on each motor. The counterbalance valve creates a partial
travel motors during stopping and overspeeding conditions.

09/11
Lab G Worksheet 2
Travel Motor
Location: Mounted on the inside of the left and right final drive housings.
Function: Converts implement/travel pump flow to motion to drive the final drive.
Forward Travel Crossover Relief Valve

Location: Located on the rear of travel counterbalance valve.
Function: Limit the maximum in the travel motor circuits.
Reverse Travel Crossover Relief Valve

Location: Located on the rear of travel counterbalance valve.
Function: Limit the maximum in the travel motor circuits.
Travel Parking Brake

Location: Inside the housings.
Function: A stack of discs and plates that prevent the final drive from turning unless the parking
brake is . The travel parking brake is spring applied and released with travel
system pressure when the is shifted.
Travel Motor Case Drain Line

Location: On the of each travel motor.
Function: Carries the motor case drain oil (internal leakage oil) back through the swivel to the case
drain filter.

09/11
Lab G Worksheet 3
Implement/Travel Pump Pressure Sensors

Location: The pressure sensors on the front side of the main implement pumps.
Function: Signals the with the pressure being produced in the implement/travel
systems.
Travel Alarm Cancel Switch

Location: On the right operator console, top left button.
Function: When activated, turns the travel alarm .
Forward Supply Line

Location: Attached to the of the counterbalance valve for the left travel motor.
Function: Supply oil to the travel motor for forward movement. Also acts as the return line for
reverse direction operation.
Reverse Supply Line

Location: Attached to the of the counterbalance valve for the left travel motor.
Function: Acts as the return line for forward direction operation. Also, supplies oil to the travel
motor for reverse movement.
Machine ECM
Location: The ECM in the compartment behind the cab.
Function: Controls the pump , the AEC system, the two speed travel solenoid valve, and
other electronic outputs while electronic inputs such as the implement pump
pressure sensors.

09/11
Lab G Worksheet 4
Travel Alarm
Location: Located below the .
Function: Alerts spectators the machine has begun to move, FORWARD or in REVERSE.
Two Speed Travel Solenoid Valve

Location: The solenoid valve mounted on the pilot manifold.
Function: When this solenoid valve is actuated by the Machine ECM, pilot system pressure is sent to
the valves in the travel motors. When the d are actuated,
the travel motor swashplates are set at the minimum angle for fast travel speed with a
reduced torque.
Two Speed Travel Switch

Location: On the right operator console, top right button.
Function: When this button is actuated by the operator, an signal is sent to the Machine
ECM. The Machine ECM then energizes or de-energizes the _ at
the correct switching pressures.
Travel Pedals/Levers
Location: On the cab floor in front of the operator's seat.
Function: Directs oil respectively to the right and left travel control spools. Allows the
operator to control the left and right track movement independent of one another or
together.
Straight Travel Pressure Switch (If Equipped)

Location: On the straight travel pilot control valve beneath the operator station.
Function: Signal the Machine ECM when the pedal is pressed.

09/11
Lab G Worksheet 5
Straight Travel Pedal (If Equipped)

Location: On the cab floor mounted on the right side of the footrest.
Function: Directs a pilot signal to the right and the left travel control spools. Allows the
operator to move the machine straight forward or reverse by pressing only pedal.
Swivel
Location: In the center of the swing frame in front of the swing drives.
Function: Provides a joint for implement/travel pump oil, pilot pump oil and travel motor
case drain oil to pass through between the upper and lower structure.
Final Drives
Location: On the rear of the roller frames.
Function: Hold the travel motor and travel counterbalance valve assemblies. Reduces the travel
motor rotational speed using gearsets in order to increase the .
Right Travel Pressure Switch

Location: On the right side of the travel control valve beneath the operator station.
Function: Signals the Machine ECM that the right travel pedal is .
Left Travel Pressure Switch

Location: On the left side of the travel control valve beneath the operator station.
Function: Signals the Machine ECM that the left travel pedal is .

09/11
Lab H: Test and Adjust Travel System Components
INFORMATION procedures for the travel system.
Lab H Worksheets
09/11
Lab H Worksheet 1
Test and Adjust Travel Crossover Relief Valves
Machine Model Date
Travel Crossover Relief Valve Test Tooling:

1 - 8T0861 Gauge
1 - 8T0856 Gauge
1 - FT2542 Track Block Assembly

Right Forward Travel
Right Reverse Travel
Left Forward Travel
Left Reverse Travel
NOTE: Test each travel crossover relief valve pressure with the engine speed dial at
Position 10. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
09/11
Lab H Worksheet 2
Measure Travel Motor Case Drain Flow
Machine Model Date
Travel Motor Case Drain Flow Tooling:

1 - FT2542 Track Block Assembly
1 - 6V9509 Face Seal Plug
1 - 6V8398 O-ring Seal
1- Hose assembly to fit travel motor case drain fitting
1- Stop watch
NOTE: For the complete procedure to test the travel motor case drain flow, refer to a testing
and adjusting Service Manual module for a 320D-336D hydraulic excavator.

Right Travel Motor
Left Travel Motor
NOTE: Test the travel motor case drain flow at three different motor positions and
then average the three flows. Flows are based on Engine Speed Dial at Position 10,
and the Travel Crossover Relief Valves set at 36800 ± 1470 kPa (5350 ± 215 psi).
Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
09/11
Lab I: Locate and Identify Swing System Components
number.
Lab I Worksheets
MATERIALS NEEDED
INDIVIDUAL OR GROUP During the presentation, use the "Lab I: Swing System Components,"
EXERCISE Worksheets to record the location and function of the components.
your results on the Lab I Worksheets.

09/11
Lab I Worksheet 1
Locate and Identify Swing System Components

Swing Control Valve

Location: Third spool from the outside of the left main control valve half.
Function: Controls the oil supply to the swing .
Fine Swing Solenoid (Cushion Swing Solenoid) (If Equipped)

Location: Mounted on the front of the swing motor.
Function: When energized, provides fine control of swing movement by eliminating
during the swing operation.
Swing Parking Brake Release Line

Location: Small line from the swing brake solenoid valve connected to the swing parking brake in the
swing drive housing.
Function: Directs pilot system oil from the swing parking brake solenoid to the swing parking brake
in order to the swing parking brake in the swing drive housing.

09/11
Lab I Worksheet 2
Locate and Identify Swing System Components
Slow Return Check Valve

Location: On the rear of the left side of the implement control valve.
Function: Provides in the system return lines. Acts as a makeup valve for
the swing motor to prevent cavitation in an overrun condition.
Swing Parking Brake Solenoid Valve

Location: The middle solenoid on the pilot manifold.
Function: When energized by the Machine ECM, the solenoid sends pilot system oil to _ the
swing parking brake.
Swing Joystick
Location: The left joystick in the cab.
Function: Controls the pilot oil used to shift the swing control spool which in turn sends hydraulic oil
to the swing to swing the machine.
Anti-reaction Valves
Location: On the bottom front of the swing motor.
Function: Help stop the swing smoothly and prevent shock loading at the end of function.
Variable Swing Priority Valve

Location: On the front of the control valve on the left valve bank.
Function: Varies the amount of supply oil that is given to the swing circuit and the spool
depending on the movement of the joysticks by the operator.

09/11
Lab J: Test and Adjust Swing System Components
INFORMATION procedures for the travel system.
Lab J Worksheets
09/11
Lab J Worksheet 1
Test and Adjust Swing System Relief Valves
Machine Model Date
Swing System Relief Valve Test Tooling:
1 - 8T0861 Gauge

Right Swing Relief Valve
Left Swing Relief Valve
NOTE: Test each travel crossover relief valve pressure with the engine speed dial at
Position 10. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
09/11
Lab J Worksheet 2
Test Swing Motor Case Drain Flow
Machine Model Date
Swing Motor Case Drain Flow Tooling:

1 - 6V9830 Cap
1- Container for Measuring
1- Stop watch

Right Swing Motor
Left Swing Motor
NOTE: Test the swing motor case drain flow at three different motor positions and
then average the three flows. The Engine Speed Dial should be at position "10".
Check to make sure the swing relief valves are set to the specification in the test
procedure. Hydraulic oil temperature should be 55° ± 5°C (131° ± 9°F).
09/11
Lab J Worksheet 3
Test Swing Brake Solenoid Valve
Machine Model Date
Swing Brake Solenoid Test Tooling:
1 - 8T8902 Tee (3/8 in. ORFS w/9/16 in. SAE thd. tap)
1 - 6V3965 Nipple, Valved (w/9/16 in. SAE ext. thd.)
1 - 3J1907 O-ring Seal
1 - 6V3079 Hose (14 ft. long w/1/8 in. NPTF ext. thd.)
2 - 6V4143 Coupler, Valved (w/1/8 in. NPTF int. thd.)
1 - 8T0856 Gauge [6000 kPa (870 psi)]
1 - 6V3989 Nipple, Open (w/1/4 in. NPTF int. thd.)

Swing Brake
NOTE: Test the swing brake solenoid with the machine controls in the following
conditions: Engine Speed Dial "10", and AEC Switch "OFF." Hydraulic oil
temperature should be 55° ± 5°C (131° ± 9°F).
09/11
Lab K: Return and Cooling System Components
number.
MATERIALS NEEDED
Lab G Worksheets
INDIVIDUAL OR GROUP During the presentation, use the "Lab K: Return and Cooling System
EXERCISE Components," Worksheets to record the location and function of the
components.
your results on the Lab K Worksheets.

09/11
Lab K Worksheet 1
Locate and Identify Cooling and Return Systems Components

Hydraulic Cooler Bypass Valve

Location: On the rear left side of the implement control valve.
Function: When open due to a restriction in the hydraulic oil cooler, hydraulic system return oil is
sent directly to the return oil filters, bypassing the _ .
Slow Return Check Valve

Location: On the rear of the left side of the implement control valve.
Function: Provides back pressure in the swing system return lines. Also acts as a
during a swing motor overrun. This prevents cavitation.
Hydraulic Oil Cooler

Location: At the left rear corner of the machine in front of the engine.
Function: Provides cooling for the oil.

09/11
Lab K Worksheet 2
Locate and Identify Cooling and Return Systems Components
Radiator
Location: At the left rear corner of the machine in front of the engine.
Function: Provides cooling for the coolant.
Case Drain Filter

Location: Behind the hydraulic tank, next to the hydraulic return filter.
Function: Filters the case drain oil from the .
Hydraulic Return Oil Filter

Location: Behind the hydraulic tank.
Function: Filter all the return oil from the circuits.
Hydraulic Fan Pump (if equipped)

Location: Connected to the pilot pump.
Function: Provide pump flow to the hydraulically driven cooling fan.

09/11 Case Study
CASE STUDY
INSTRUCTOR NOTE The following section provides a troubleshooting case study with a
suggested troubleshooting process. You may want to work through the
case study and make your own notes. The actual student case study,
without the possible solution, is located in the Student Materials Section.
This case study is designed to promote logical troubleshooting

procedures. To do this, the students can complete the exercise in either
of the following ways:
A. Each student may complete the exercise individually and then

discuss the solution as a class.
B. Students may complete the exercise in small groups and then

discuss the solution as a class.
Summarize the results for each step using flipcharts or the blackboard.
You may want to provide the students with possible answers after the
discussion.
Students should use their class notes and other reference materials to
complete the exercise.
09/11 Case Study
"D" Series Excavator Hydraulic System Case Study
DIRECTIONS Students should use the service manual and class notes to complete the
exercise. Have the students answer the questions on the Troubleshooting
Exercise Worksheet. Discuss the exercise with the students after they
have had time to answer the exercise questions.
The following exercise is based on a possible field complaint.

SITUATION
A customer is using a 320D-336D in a tamping operation. The operator

of the excavator reported to his supervisor that the machine's boom drifts
down after four or five tamping passes. When tamping, the stick is in a
vertical position and the tamping height is 3.5 to 4.0 inches.
A dealer service technician was sent to investigate the problem.

09/11 Case Study
"D" Series Excavator Hydraulic System Troubleshooting Worksheet 1
ISOLATE PROBLEM The first step in in a troubleshooting process is to gather information

before starting any work on the machine. If possible talk to the operator.
GATHER INFORMATION Also, check the repair history of the machine and the Caterpillar Service
Information Retrieval System (SIRS). List at least three questions you
would ask an operator to help in identifying that a problem exists?
Possible answers:
Verify the problem exists. Operate the machine to duplicate the problem,
VERIFY
preferably under similar operating conditions. Compare the operation to
a known good machine. Perform sensory checks such as looking,
listening, touching, and smelling to verify a problem exists.
When troubleshooting always perform a visual inspection first. Look for
the obvious. List at least three typical items that should be inspected
PERFORM VISUAL during a visual inspection. Possible answers:
INSPECTION
After verifying a problem exists, state in your own words what the
problem is. Caution: Do not identify the solution. Possible answer:
STATE PROBLEM
09/11 Case Study

LIST POSSIBLE The next step in the process is to list all of the possible causes of the
FAULTS
problem. Identify all systems and components that could be causing the
problem, including the least obvious. List at least four things that could
be checked. Possible answers:
Now, create a list of tests that should be performed and describe what the
DEVISE TESTS AND tests would determine. Prioritize the tests as to which sequence they
DETERMINING ROOT should be performed in. As a general rule, always do the easiest tests
CAUSE first. Also, list diagnostic tooling required. Identify at least four tests to
perform. (NOTE: the rankings are only suggested.)
Check pilot pressure to the boom drift reduction valve. If pilot

pressure is present (at specification) during a boom down and
there is no residual pressure when the boom down is stopped,
then the shuttle valve that vents the dump spool is receiving the
correct signals.
Tooling needed: Pressure gauge
Perform basic drift test on the boom. Doing this test can verify
that there is a real problem outside of specifications.
Tooling needed: Tape measure
Check the boom up line relief setting. If the setting is too low,
then the boom up line relief may need adjusted.
Tooling needed: Pressure gauge
09/11 Case Study

DEVISE TESTS AND Exchange the boom up and the boom down line reliefs. This
DETERMINING ROOT
will determine if the boom up line relief is defective.
CAUSE
(CONTINUED) Tooling needed: Wrenches
REPAIR FAULT After isolating the component, which you suspect from your test results
is causing the problem, either adjust or replace the component.
Circle the best response:

If during your tests you discovered that there was residual pilot pressure
to the boom drift reduction valve when the boom joystick was in the hold
position. Which one of the following components would you inspect?
1. Boom joystick
2. Boom drift reduction valve
3. Boom I spool
4. Boom cylinder rod end line relief
If during your tests you discovered that the boom cylinder head end line
relief was relieving at a pressure below specification what would be the
next step to take.
1. Adjust the boom cylinder head end line relief
2. Replace the boom cylinder head end line relief
3. Replace the boom drift reduction valve
4. Inspect the Boom II spool
If the boom cylinder head end line relief valve has been adjusted, and
switching the boom cylinder head end line relief and the boom cylinder
rod end line relief stops the downward drift, what would be the next step
to take.
1. Adjust the boom cylinder head end line relief
2. Replace the boom cylinder head end line relief
3. Replace the boom drift reduction valve
4. Inspect the Boom II spool
09/11 Case Study
"D" Series Excavator Electronic Control System Troubleshooting Worksheet 5
VERIFY REPAIR After completing the repair, always verify the machine is operating
correctly. List at least three things you would do to make sure the repair
was done correctly.
1.
2.
3.
4.
5.
Complete the service report after finishing the job.

09/11 Case Study
320D-336D Hydraulic Excavator Hydraulic

SystemsOperation Posttest
INSTRUCTOR NOTE Classroom Posttest:

Students may refer to their course material and class notes when taking
the posttest.
Students may not consult with others during the posttest.
INDIVIDUAL EXERCISE Procedure:

Explain to the class how to fill out the posttest.
After the completion of this exercise discuss the completed post test with
the students.
MATERIALS NEEDED
320D-336D Hydraulic Excavator Hydraulic Systems Operation
Posttest
09/11 Posttest
320D-336D HYDRAULIC EXCAVATOR

HYDRAULIC SYSTEMS OPERATION POSTTEST
Directions: Modified True/False. If a question is false, underline or circle the word or words that
make the statement incorrect and replace with word(s) to make the statement correct.
Example: F 1. This is an engine class. a hydraulic system
1. When investigating a power complaint, first determine if the complaint is hydraulic or

engine related.
2. When the implement or travel controls are in use, the implement or travel pressure is
regulated by the NFC relief valve.
3. The Machine ECM receives an electrical signal from the idler pump pressure sensor
during the swing function.
4. The travel system pressure can be checked while stalling an implement function.
5. When power shift pressure to the implement pump control valves increases, the pumps
destroke.
6. The variable swing priority valve is controlled by the swing priority pressure reducing
valve.
7. Boom pilot pressure controls the swing priority pressure reducing valve.
8. The Stick II stick in pilot signal is controlled by the boom down pilot signal going to the
boom priority pressure reducing valve.
9. The NFC relief valve system ensures the implement pumps upstroke or destroke
depending on control valve spool movement.
10. The maximum pressure during level travel is regulated by the travel crossover relief
valve.
11. Power shift signal pressure is controlled by the monitor.
12. The power shift PRV pressure oil comes directly from the pilot manifold.
13. The implement pumps upstroke when the power shift solenoid receives a decrease in
electrical signal from the Machine ECM.
09/11 Posttest
14. The Machine ECM regulates NFC pressure to the implement pumps to keep the engine
from stalling.
15. The two horsepower adjustments on the implement pump control valve controls the
destroking of the pump.
16. The Boom I and Boom II control valves move at the same time when Boom Up function
is activated.
17. It is possible to have the stick re-generation not function during a Stick In operation.
18. When the implement pumps are at standby, the NFC signal pressure is lowest.
19. The stick unloading valve is shifted during stick in operation by the Stick In pilot
pressure.
20. The implement pump flow is controlled by three different signal pressures sent to the
pump control valves.
21. On all 320Ds, one of the signal pressures that control pump flow is the negative flow
control pressure.
22. The 320D and the 322D excavators hydraulic systems operate differently.
23. When multiple controls are activated, the highest system pressure from the right or left
half of the implement control valve is regulated by the main relief valve.
24. Power shift pressure can only be calibrated using the Service Tool and ET software.
25. Diagnostic information is available from the monitor panel or by using ET.
09/11 Posttest
Directions: Fill In The Blank. Any reference material and class notes may be used to determine the
correct answers.
1. The travel crossover relief valves are adjusted to what pressure?
2. What constant power shift pressure is set during P-Q testing?
3. The boom head end and stick rod end line relief valves are adjusted to what pressure?
4. The remaining implement line relief valves are adjusted to what pressure?
5. The main relief valve is adjusted to what pressure for implement functions?
6. The swing motor left and right relief valve pressure setting is adjusted to what pressure?
7. The travel motor crossover relief valve pressure setting is adjusted to what pressure?
8. The pilot system pressure is adjusted to what pressure?
9. The power shift pressure is adjusted to what pressures during the calibration procedure?
and
10. The travel and swing parking brakes require what pressure to release?
11. The stick unloading valve requires what rod end return pressure to shift?
09/11 Posttest
Directions: Match the component with the correct function by placing the letter next to the
component.
Pilot Pump A. Provides priority oil flow to the Boom Up and
Swing operations during multiple implement
Power Shift Pressure Solenoid operations.
B. Control signals from the left and right sections of
Boom and Swing Priority Pressure the implement control valve
Reducing Valves
C. Receives signals from pressure switches and sensors.
Implement/Swing Pressure Switch Sends a PWM signal to the power shift solenoid.
D. When activated, sends drive pump flow to both
Boom Drift Reduction Valve travel motors and idler pump flow to the implement
and swing functions.
Swing Anti-reaction Valves
E. Driven by the right implement pump. Provides pilot
Hydraulic Actuation Valve oil flow to the pilot oil system.
F. Provides an average pressure signal to the
Slow Return Check Valve Implement pump control valves based upon the
output of the idler implement pump and the drive
Swing Brake Solenoid Valve implement pump.
G. Reduces wag during swing operations.
Hydraulic Actuation Lever Switch
H. If this switch is closed, the Hydraulic Actuation
Travel Pressure Switches Solenoid Valve is energized.
I. Controlled by the Machine ECM. Provides a signal
Negative Flow Control Signals
to the implement pump control valves to control
pump output under load.
Straight Travel Valve
J. Prevents the boom cylinders from drifting down
Engine and Pump Control under load
K. Receives a signal from the Machine ECM and sends
Cross Sensing Signal pilot system oil to release the swing brake.
Stick Unloading Valve L. Signals the Machine ECM when L or R travel is

actuated.
M. Controlled by the Hydraulic Actuation Solenoid on
the pilot manifold. When activated, provides pilot
oil to the pilot oil system
N. Signals the Machine ECM when an implement or
swing operation is activated.
O. Provides a back pressure in the return oil lines.
P. After Stick In return pressure becomes excessive
this valve shifts, opening another return oil passage
for Stick In return oil.
SERV1852 -1- Instructor Module
02/08 Posttest
320D-330D HYDRAULIC EXCAVATOR

HYDRAULIC SYSTEMS OPERATION POSTTEST
ANSWERS
Directions: Modified True/False. If a question is false, underline or circle the word or words that
make the statement incorrect and replace with word(s) to make the statement correct.
Example: F 1. This is an engine class. a hydraulic system
T 1. When investigating a power complaint, first determine if the complaint is hydraulic or

engine related.
F 2. When the implement or travel controls are in use, the implement or travel pressure is
regulated by the NFC relief valve. main
T 3. The engine and pump control module receives an electrical signal from the left pump
pressure sensor during the swing function.
T 4. The travel system pressure can be checked while stalling an implement function.
T 5. When power shift pressure to the implement pump regulators increases, the pumps
destroke.
T 6. The variable swing priority valve is controlled by the swing priority pressure reducing
valve.
F 7. Boom pilot pressure controls the swing priority pressure reducing valve. swing
F 8. The Stick II, Stick In pilot signal is controlled by the boom down pilot signal going to the
boom priority pressure reducing valve. up
T 9. The NFC relief valve system ensures the implement pumps upstroke or destroke
depending on control valve spool movement.
F 10. The maximum pressure during level travel is regulated by the travel crossover relief
valve. main
F 11. Power shift signal pressure is controlled by the monitor. engine and pump control
F 12. The power shift PRV pressure oil comes directly from the pilot manifold. filter
T 13. The implement pumps upstroke when the power shift solenoid receives a decrease in
electrical signal from the engine and pump control module.
02/08 Posttest
F 14. The Engine and Pump Control Module regulates NFC pressure to the implement pumps
to keep the engine from stalling. power shift
T 15. The two horsepower adjustments on the implement pump regulator controls the
destroking of the pump.
F 16. The Boom I and Boom II control valves move at the same time when Boom Up function
is activated. different times
T 17. It is possible to have the stick re-generation not function during a Stick In operation.
F 18. When the implement pumps are at standby, the NFC signal pressure is lowest. highest
F 19. The stick unloading valve is shifted during stick in operation by the Stick In pilot
pressure. rod end
T 20. The implement pump flow is controlled by three different signal pressures sent to the
pump regulators.
T 21. On all 320D's, one of the signal pressures that control pump flow is the negative flow
control pressure.
F 22. The 320D and the 324D excavators Hydraulic systems operate differently. similarly
T 23. When multiple controls are activated, the highest system pressure from the right or left
half of the implement control valve is regulated by the main relief valve.
F 24. Power shift pressure can only be calibrated using the Service Tool and ET software. or
monitor panel
T 25. Diagnostic information is available from the monitor panel or by using ET.
02/08 Posttest
Directions: Fill In The Blank. Any reference material and class notes may be used to determine the
correct answers.
1. The travel crossover relief valves are adjusted to what pressure? 36800 kPa (5350 psi)
2. What constant power shift pressure is set during P-Q testing? 2400 kPa (350 psi)
3. The boom head end and stick rod end line relief valves are adjusted to what pressure?
36800 kPa (5350 psi)
4. The remaining implement line relief valves are adjusted to what pressure? 36800 kPa (5350 psi)
5. The main relief valve is adjusted to what pressure for implement functions? 34300 kPa (4950 psi)
6. The swing motor left and right relief valve pressure setting is adjusted to what pressure?
26000 kPa (3750 psi)
7. The travel motor crossover relief valve pressure setting is adjusted to what pressure?
36800 kPa (5350 psi)
8. The pilot system pressure is adjusted to what pressure? 4100 kPa (595 psi)
9. The power shift pressure is adjusted to what pressures during the calibration procedure?
500 kPa (70 psi) and 2500 kPa (362 psi)
10. The travel and swing parking brakes require what pressure to release? 3030 kPa (440 psi)
11. The stick unloading valve requires what rod end return pressure to shift? 10390 kPa (1510 psi)
02/08 Posttest
Directions: Match the component with the correct function by placing the letter next to the
component.
E Pilot Pump A. Provides priority oil flow to the Boom Up and
Swing operations during multiple implement
I Power Shift Pressure Solenoid operations.
B. Control signals from the left and right sections of
A Boom and Swing Priority Pressure the implement control valve
Reducing Valves
C. Receives signals from pressure switches and
N Implement/Swing Pressure Switch sensors. Sends a PWM signal to the power shift
solenoid.
J Boom Drift Reduction Valve D. When activated, sends drive pump flow to both
travel motors and idler pump flow to the implement
G Swing Anti-reaction Valves and swing functions.
M Hydraulic Actuation Valve E. Driven by the right implement pump. Provides

pilot oil flow to the pilot oil system.
O Slow Return Check Valve F. Provides an average pressure signal to the
implement pump regulators based upon the output
K Swing Brake Solenoid Valve of the left implement pump and the right implement
pump.
H Hydraulic Actuation Lever Switch
G. Reduces wag during swing operations.
L Travel Pressure Switches H. If this switch is closed, the Hydraulic Actuation
Solenoid Valve is energized.
B Negative Flow Control Signals
I. Controlled by the Machine ECM. Provides a signal
to the implement pump regulators to control pump
D Straight Travel Valve output under load.
C Engine and Pump Control J. Prevents the boom cylinders from drifting down
under load
F Cross Sensing Signal K. Receives a signal from the Machine ECM and
sends pilot system oil to release the swing brake.
P Stick Unloading Valve
L. Signals the Machine ECM when L or R travel is
actuated.
M. Controlled by the Hydraulic Actuation Solenoid on
the pilot manifold. When activated, provides pilot
oil to the pilot oil system
N. Signals the Machine ECM when an implement or
swing operation is activated.
O. Provides a back pressure in the return oil lines.
P. After Stick In return pressure becomes excessive
this valve shifts, opening another return oil passage
for Stick In return oil.

Global Service Learning: 300D Series Hydraulic Excavators - Tier Iii Engines

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SERV1852-02

GLOBAL SERVICE LEARNING

300D SERIES HYDRAULIC

Service Training Meeting Guide

After completion of this module, the student will be able to:

2. Given a machine and the appropriate service literature perform the

MODULE OBJECTIVES (continued)

3. Given all reference material and class notes:

4. Given all reference material and class notes, on a posttest:

Lab A: Locate and Identify Pilot System Components

MATERIALS NEEDED Lab A Worksheets

Fill in the blank statements regarding component location and function.

Review results with your instructor.

Example: 9 Pilot Pump

Parts Manual Part Name: Pump Gp - Gear Part No.: 186-6423

Parts Manual Part Name: Part No.:

Pilot System Pressure Test Port

Parts Manual Part Name: Part No.:

Pilot System Pressure Relief Valve

Parts Manual Part Name: Part No.:

Pilot System Accumulator

Parts Manual Part Name: Part No.:

Swing Parking Brake Solenoid Valve

Parts Manual Part Name: Part No.:

Hydraulic Actuation Control Valve

Hydraulic Actuation Solenoid Valve

Parts Manual Part Name: Part No.:

Hydraulic Actuation Lever

Parts Manual Part Name: Part No.:

Power Shift Solenoid Valve

Parts Manual Part Name: Part No.:

Pilot Pressure Release Line for Swing Parking Brakes

Parts Manual Part Name: Part No.:

Two Speed Travel Solenoid Valve

Parts Manual Part Name: Part No.:

Implement/Swing Resolver Valve

Parts Manual Part Name: Part No.:

Swing/Boom Priority Valves

Parts Manual Part Name: Part No.:

Left Travel Pressure Switch

Parts Manual Part Name: Part No.:

Implement/Swing Pressure Switch (AEC)

Parts Manual Part Name: Part No.:

Straight Travel Pressure Switch

Parts Manual Part Name: Part No.:

Right Travel Pressure Switch

Parts Manual Part Name: Part No.:

Pilot System S•O•S Fitting

Parts Manual Part Name: Part No.:

Lab B: Test and Adjust Pilot System Relief Valve

MATERIALS NEEDED Lab B Worksheets

Machine Model Date

Serial Number Service Meter Hours

Tooling for Pilot Relief Valve Test

1 - 8T0856 Gauge [6000 kPa (870 psi)]

Item Specification Actual

Lab C: Locate and Identify Implement/Travel Pumps and

Fill in the blank statements regarding component location and function.

Review results with your instructor.

Example: 9 Pilot Pump

Parts Manual Part Name: Pump Gp - Gear Part No.: 186-6423

Implement/Travel Pump Group

Parts Manual Part Name: Part No.: