Calibration Relief Valve Excavator

EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGIN...
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Producto: EXCAVATOR
Modelo: E200B EXCAVATOR 4SG04715
Configuración: EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGINE
Pruebas y Ajustes
E200B & EL200B EXCAVATORS HYDRAULIC AND ELECTRONIC SYSTEMS
Número de medio -SENR4527-01 Fecha de publicación -01/01/1991 Fecha de actualización -11/10/2001
Hydraulic System Testing And Adjusting
Introduction
Hydraulic oil pressure can remain in the hydraulic systems on this

machine after the engine and pump have been stopped. Serious injury
can be caused if this pressure is not released before any service is done
on the hydraulic systems. To prevent possible injury, refer to section,
Release of Pressure in the Hydraulic System before any fitting, hose or
component is loosened, tightened, removed or adjusted.
When possible, the bucket must always be lowered to the ground before
service is started. When it is necessary for the boom to be in the raised
position while tests or adjustments are done, be sure that boom, stick
and bucket have correct support.
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.
During a diagnosis of the hydraulic system, remember that correct oil temperature, flow and
pressure are necessary for correct operation. Pump output (oil flow) is a function of engine speed
(rpm). Oil pressure is caused by resistance to the flow of oil.
Each of the implement circuits has a load check valve to prevent cylinder drift during spool
movement. Each circuit also has makeup valves for flow of oil to both ends of the cylinders and
motors and there is a line relief valve for each of the cylinder and swing motor circuits.
Visual checks and measurements are the first steps when troubleshooting a possible problem. Then
do the Checks During Operation and last the checks and adjustments on the machine.
Use a stopwatch, a magnet and a mm (inch) ruler to measure the following basic checks.
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EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGIN... Page 2 of 36
Visual Checks
A visual inspection of the system is the first step when troubleshooting a problem. Make the
inspection with the engine off and the implements lowered to the ground.
1. Check the level of the oil in the hydraulic tank. Slowly loosen the hydraulic tank air breather cap
and release the pressure before the filler cap is removed.
2. Remove the filter element and check it for material that would give an indication of damage to a
component.
3. Inspect all lines and connections for damage or leaks.
4. Inspect control linkage for bent, broken or damaged components.
Checking During Operation

The checks during operation can be used to find leakage in the system. They can also be used to find
a valve or pump that is not working correctly. The speed of rod movement or the torque on a motor
can be used to check the condition of the cylinders, motors and the pumps.
Raise and lower the boom. Move the stick in and out. Open and close the bucket. Move the swing
control for swing right and swing left. Do each of these operations several times.
1. Pilot system operation. Since the pilot system controls the movement of spools in the main control
valves, it is important the pressure and flow of oil from the gear-type pump be according to
specifications. The pressure in the pilot system is controlled by the pilot relief valve.
2. During all machine operations, a main relief valve pressure setting that is too low will result in
increased cycle times and/or the sound of the main relief valve opening.
3. A main relief pressure that is too high will cause a decrease in the service life of hoses and
components.
4. For individual circuit operation, a line relief valve pressure setting that is too low will result in
increased cycle times and/or the sound of the relief valve opening for that circuit.
5. Check cycle times for each of the circuits: boom, bucket/shovel, stick and swing. Cycle times that
are longer than those shown in operational Tests in "Hydraulic System Testing And Adjusting"
could be the result of insufficient pilot system pressure, leakage past cylinder seals, pump wear,
pump speed (rpm), faulty relief valve (main or line) or pump control system adjustment.
6. Drift rate for the boom, bucket/shovel and stick circuits are greater than those shown in
Operational Tests in "Hydraulic System Testing And Adjusting".
Circuit drift (drifting) is caused by leakage past cylinder piston, O-ring seals in the control valves,
check valves or makeup valves that do not seat correctly. Poor adjustment or fit in the pilot and main
control valves will also cause drifting.
7. Check machine travel circuits. Operate the machine in the FORWARD and REVERSE direction
without moving the control levers for steering. If the machine does not travel in a straight line, there
could be a problem with the negative control signal to the pumps, motor wear or a line relief valve
that is not operating correctly.
Operational Test
Engine Speed
6V3121 Multitach Group.
The test conditions for each operational test should be as follows:
1. Set the engine speed at 1950 ± 50 rpm, high idle, no load.
2. Raise hydraulic oil temperature to 45 to 55°C (115 to 130°F)
3. Set the main relief pressure at 31400 kPa (4600 psi).
4. Travel crossover relief pressure of 33300 kPa (4800 psi) for Travel test.
5. Swing relief pressure of 23500 kPa (3400 psi) for Swing test.
6. Line relief pressure of 33300 kPa (4800 psi) for Cylinder test.
7. Turn the power mode switch to mode III position.
Travel On Level Ground

6V3121 Multitach Group.6V4151 Pressure Gauge Kit.
StopwatchTape measure
Test Conditions
1. Travel test ground must be hard and as level as possible, and at least 25 m (27.5 yards) long.
2. Draw 25 m (27.5 yards) straight line on the travel test ground as a reference line.
3. Place the machine so that one track is perfectly in line with the reference line. Put the machine in
the travel position shown in the illustration.
4. Bucket must be empty.
Test Procedure
1. Start the engine. Move the accelerator lever at the full-load position. Then move the machine by
operating both travel levers at the same time.
2. The first 5 m (5.5 yards) are for a preliminary run. Measure the time required for the machine to
travel the remaining 20 m (22 yards) in each direction.
3. Measure the travel deviation from the reference straight line.
Time Required:
High speed ... 17.5 ± 1.5 sec.
Low speed ... 28.0 ± 3.0 sec.
Travel Deviation From Straight Line:
High speed ... 1150 ± 350 mm (45.3 ± 13.8 in.)
Low speed ... 1150 ± 350 mm (45.3 ± 13.8 in.)
Travel On Level Ground (Optional Test)

In case of difficulty to find suitable ground for Travel Test on Level Ground, this test will be done as
the substitute of the above.
Stopwatch
Test Conditions
1. Place the machine on level ground.
Test Procedure
1. Raise a track for the test as shown in figure.
2. Put a mark on a shoe of the raise track.
3. Pull the accelerator lever to full-load position, to run the raised track.
4. Measure the time required for the track to turn three complete cycles in each direction.
Time Required:
High speed ... 22 ± 2 sec./3 turns
Low speed ... 33.5 ± 2.5 sec./3 turns
Movement On Slope
Stopwatch150 mm (6 in.) scale
Test Condition
1. Let the machine go up on a slope of 19° and stop it. The slope surface must be hard and smooth.
2. Put the machine in a posture as shown in the figure below.
3. Bucket should be empty.
Test Procedure
1. Put marks on both track and ground to indicate its relative position to the slope.
2. Stop the engine and count three minutes with a stopwatch.
3. Measure, with a scale, how much distance the tracks have moved on the slope.
Drift ... 15 ± 5 mm (0.6 ± 0.2 in.)
Swing Speed And Drift (On Level Ground)

ScaleStopwatch
Test Conditions
1. Place the machine on level ground and put the machine in a position shown in figure.
2. Put marks on both inner and outer races of the swing bearing to indicate relation of two positions.
3. Bucket should be empty.
Test Procedure
1. Tilt the control lever to the left or right and measure time for 180° swing.
2. Return the swing control lever to NEUTRAL at the end of the 180° swing and measure the
amount of drift (overswing) by the marks put on the swing bearing.
Swing Time:
Right swing ... 4.7 ± 0.5 sec.
Left swing ... 4.7 ± 0.5 sec.
Swing Drift:
Right swing ... 1250 ± 150 mm (49 ± 6 in.)
Left swing ... 1250 ± 150 mm (49 ± 6 in.)
Swing Speed And Drift (On Slope)

6V3121 Multitach Group.
ScaleStopwatch
Test Conditions
1. Place the machine on a slope of 12°.
2. Put the implements to maximum reach and fill the bucket with soil.
3. The bucket load should be 10300N (2315 lb.).
Test Procedure (Speed)
1. Put positional marks on inner and outer races of the swing bearing. Place the upper structure at 90
degrees angle to tracks, that is, at 3 or 9 o'clock position.
2. Measure the time needed for swing counter clockwise from 3 o'clock to 12 o'clock positions, and
the time of clockwise from 9 o'clock to 12 o'clock positions.
Test Procedure (Drift) (Swing Brake Released)
1. Stop the machine on a slope of 12 degree. Place the upper structure at 3 o'clock position as
shown.
2. Put marks on inner and outer races of the swing bearing.
3. Turn ON Swing Brake Release Switch, with the engine kept running.
4. Measure swing drift for three minutes on the circumference of the swing bearing.
5. Turn the upper structure 180 degree angle to 9 o'clock position. Perform steps 2, 3 and 4.
Test Procedure (Drift) (Swing Brake Locked)
1. Stop the machine on a slope of 12 degree. Place the upper structure at 3 o'clock position as
shown.
2. Put marks on inner and outer races of the swing bearing.
3. Stop the engine.
4. Measure swing drift for three minutes on the circumference of the swing bearing.
5. Turn the upper structure 180 degree angle to 9 o'clock position. Perform steps 2, 3 and 4.
Swing Time:
Swing from 3 o'clock position ... 4.7 ± 0.5 sec.
Swing from 9 o'clock position ... 4.7 ± 0.5 sec.
Swing Drift (Swing Brake Released):
Drift from 3 o'clock position ... 210 ± 70 mm (8.3 ± 2.8 in.)
Drift from 9 o'clock position ... 210 ± 70 mm (8.3 ± 2.8 in.)
Swing Drift (Swing Brake Locked):
Drift from 3 o'clock position ... < = 10 mm (0.4 in.)
Drift from 9 o'clock position ... < = 10 mm (0.4 in.)
Cylinder Rod Drift

8T0470 Thermometer Group.
EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGI... Page 10 of 36
StopwatchScale
Test Conditions
1. Place the machine on level ground as shown figure.
2. Fill the bucket with soil.
3. The bucket load should be 10300N (2315 lb.).
4. Stop the engine.
Test Procedure
Test for boom cylinders and stick Cylinder Rod Drift.
1. Start the engine.
2. Fully extend the bucket cylinder.
3. Fully retract the stick cylinder.
4. Raise the boom until its upper surface becomes parallel to the ground. Stop the engine.
5. Measure how much distance each rod has moved in a minute after the start.
Test for Bucket Cylinder Rod Drift
1. Start the engine.
2. Fully extend the bucket cylinder.
3. Raise the boom high enough to suspend the stick perpendicular to the ground and stop the engine.
4. Measure the rod movement.
Rod movement:
Boom cylinder ... 14 ± 6 mm/min. (0.6 ± 0.2 in./min.)
Stick cylinder ... 14 ± 6 mm/min. (0.6 ± 0.2 in./min.)
Bucket cylinder ... 14 ± 6 mm/min. (0.6 ± 0.2 in./min.)
Cylinder Operating Speed

6V3121 Multitach Group.6V4161 Pressure Gauge Kit.8T0470 Thermometer Group.
Stopwatch
Test Conditions
1. Place the machine on level ground.
2. Bucket must be empty.
Test Procedures
Boom Cylinders
Fully retract bucket and stick cylinders.
Extension test ... Measure the operating time required for the boom cylinders to reach full extension
position from bucket-on-ground condition.
Retraction test ... Measure the operating time required for the bucket to contact the ground from full
extension position of boom cylinders.
Stick Cylinder
Position the boom upper surface parallel to the ground and fully extend the bucket cylinder.
Extension test ... Measure the operating time required for the stick cylinder to reach full extension
position from full retraction position.
Retraction test ... Measure the operating time required for the stick cylinder to reach full retraction
position from full extension position.
Bucket Cylinder
Position the boom upper surface parallel and the stick perpendicular to the ground.
Extension test ... Measure the operating time required for the bucket cylinder to reach full extension
position from full retraction position.
Retraction test ... Measure the operating time required for the bucket cylinder to reach full retraction
position from full extension position.
Operating Speed:
Boom (Extension) ... 3.7 ± 0.8 sec.
Boom (Retraction) ... 3.2 ± 0.6 sec.
Stick (Extension) ... 5.1 ± 1.0 sec.
Stick (Retraction) ... 3.4 ± 0.7 sec.
Bucket (Extension) ... 4.4 ± 0.9 sec.
Bucket (Retraction) ... 2.6 ± 0.6 sec.
Release Of Pressure
Release the pressure in the implement hydraulic circuits (boom, stick and bucket) before any
hydraulic lines or components are disconnected or removed. Follow this procedure:
1. Fully retract the rod in the stick cylinder.
2. Adjust the position of the bucket so that it will be flat on the ground when the boom is lowered.
3. Lower the boom until the bucket is flat on the ground.
4. Shut off the engine and put the hydraulic activation control lever in the LOCK position.
5. Move the control levers for boom, bucket, stick and swing full strokes. This will relieve any
pressure that might be present in the pilot system.
6. Slowly loosen the air breather cap on the hydraulic tank and release the pressure.
7. Tighten the air breather back on the hydraulic tank.
8. The pressure in the system has been released and lines and components can be removed.
Relief Valves
Specifications
Adjustment Procedures
6V3121 Multitach Group.6V4161 Pressure Gauge Kit.1U8761 Flow Meter.
NOTE: The above figures indicate approximate value. Use pressure gauge for adjustment.
Preparation
1. Place the machine on level ground and stop the engine.
2. Release the remaining pressure in the hydraulic system according to the section, Release of
Pressure.
Pump Upper Side

(1) Tap for front pump. (2) Tap for rear pump.
3. Connect 60000 kPa (8700 psi) pressure gauge to pump. Tap (1) is for the front pump. Tap (2) is
for the rear pump.
Pilot Manifold
(3) Tap.
4. Connect 6000 kPa (870 psi) pressure gauge to tap (3) of the pilot manifold.
5. Start the engine and raise hydraulic oil temperature to 45 to 55°C (115 to 130°F).
6. Pull the accelerator lever to the rearmost position. Confirm whether the engine is running at the
high idle speed of 1950 ± 50 rpm under no load.
7. To do steps 5 and 6, use the thermometer contained in 1U8761 Flow Meter and the 6V3121
Multitach.
Normal operations (see characteristic curves) of the engine and pumps are necessary for the pressure
adjustments. If the results of the pressure adjustment are not correct, then the engine and pump
characteristic curve needs to be checked.
Temporary Setting Of Main Relief Pressure
Bucket Position
1. Loosen locknut of adjusting screw on the line relief valve for bucket cylinder rod end (5), and turn
adjusting screw a quarter turn clockwise.
2. Hold the bucket control lever at fully dump position. Turn in or out the adjusting screw of main
relief valve (4) until adjusted to 35300 kPa (5120 psi).
Control Valve (Bottom View)

(4) Main relief valve. (5) Line relief valve bucket cylinder (rod end).
Line Relief Valves

Head end line relief valves of stick (6), bucket (7) and boom (8) are installed on top of the control
valve.
Control Valve (Top View) Line Relief Valve

(6) Stick cylinder (head end). (7) Bucket cylinder (head end). (8) Boom cylinder (head end).
Rod end line relief valves of boom (9), bucket (5) and stick (10) are installed on bottom of the
control valves.

(5) Bucket cylinder (rod end). (9) Boom cylinder (rod end). (10) Stick cylinder (rod end).
Keep the machine in position as shown. Adjust pressure to 33300 ± 980 kPa (4800 ± 140 psi) (6KF1
-676, 7DF1-1539) or 34300 ± 980 kPa (5000 ± 140 psi) (6KF677-UP, 7DF1540-UP), then tighten
locknuts to a torque of 29 ± 3 N·m (22 ± 2 lb ft).
After line relief valve adjustments, adjust main relief valve to its normal setting. Reference the
section main relief valve.
Stick Cylinder
Stick Out
1. Operate the stick control lever for stick OUT, and hold the lever in this position. Then adjust the
pressure for stick cylinder (rod end) (10).
2. Operate the stick control lever for stick IN, and adjust pressure for stick cylinder (head end) (6) in
the same way as in Step 1.
Bucket Cylinder
Bucket Close
1. Operate control lever of the bucket for close. And hold the lever in this position. Then adjust
pressure for bucket cylinder (head end) (7).
2. Operate the bucket control lever for bucket dump, and adjust pressure for bucket cylinder (rod
end) (5) in the same way as in Step 1.
Boom Cylinders
Boom Raise
Operate the boom control lever for raise, and hold the lever in this position. Then adjust pressure for
boom cylinder (head end) (8).
Boom Lower
Operate the boom control lever for lowering. And hold the lever in this position. Then adjust
pressure for boom cylinder (rod end) (9).
NOTE: If flat ground prevents the machine from lowering its boom, line relief valve on head end
(8) should be replaced with the one in rod end (9) for convenience of the adjustment. Adjust its
pressure in full extension of the cylinder.
* After adjustment, put line relief valves (8) and (9) back in their respective places.
Travel Motor Relief Valves
(11) Track. (12) Travel motor.
1. Insert a stopper (round bar) between the track link and the lower teeth of the right or left travel
sprocket wheel to block the track.
2. Move the right travel control lever to the FORWARD position and hold the lever as it is.
Crossover Relief Valve

(13) Travel motor (FORWARD). (14) Travel motor (BACKWARD).
3. Adjust pressure to 33300 ± 980 kPa (4800 ± 140 psi) (6KF1-676, 7DF1-1539) or 34300 ± 980
kPa (5000 ± 140 psi) (6KF677-UP, 7DF1540-UP) by adjusting screw of crossover relief valve (14).
Tighten lock nut to specified torque of 69 ± 7 N·m (50 ± 5 lb ft).
4. Fit the stopper in the reverse direction of the track.
5. Move the right travel control lever to the REVERSE position and hold it in this position.
6. Adjust pressure by adjusting screw of crossover relief valve (13).
7. Adjust crossover relief valve pressure of the left motor in the same way as that of the right.
Swing Motor Relief Valve

1. Set the swing lock pin in lock position.
2. Move the swing control lever to the right for clockwise swing. Hold the control lever in this
position.
Viewed From Top Of Machine Swing Relief Valve

(15) Relief valve (clockwise). (16) Relief valve (counterclockwise).
3. Check the pressure of relief valve (15).
4. Move the swing control lever to the left for counterclockwise swing. Check the pressure of relief
valve (16).
5. If the pressure deviates from 23500 ± 980 kPa (3400 ± 140 psi), replace the relief valve.
Main Relief Valve

(4) Main relief valve.
1. Move the bucket control lever for CLOSE, and hold it in this position.
2. Loosen the adjusting screw of main relief valve (4). Adjust it to the pressure of 31400 ± 490 kPa
(4600 ± 72 psi).
3. Tighten the locknut to a torque of 29 ± 3 N·m (22 ± 2 lb.ft.).
Pilot Relief Valve
Pilot Manifold
(17) Pilot relief valve.
1. Loosen the locknut of pilot relief valve (17), then adjust pressure to 3450 +490 -0 kPa (500 +72 -0
psi) (6KF1-676, 7DF1-1539) or 3750 +200 -290 kPa (540 +28 -43 psi) (6KF677-UP, 7DF1540-UP)
using the adjusting screw.
2. Tighten the locknut to a torque of 16 ± 1 N·m (12 ± 1 lb.ft.).
Adjustment Procedure For Automatic Travel Speed Change -

(6KF590-UP, 7DF1405-UP)
Top Of Rear Pump

(20) Tap.
Right Travel Motor

(21) Speed change port.
Bottom Of Rotary Joint

(22) Adjusting screw for automatic travel speed (ATS) valve.
Preparation
1. Connect 49000 kPa (7100 psi) pressure gauge to tap (20) of the rear pump.
2. Disconnect the hydraulic line from speed change port (21) of the right travel motor and connect
4900 kPa (700 psi) pressure gauge to the line. Install a plug to port (21).
3. Put a chock in the FORWARD direction of the right track.
4. Run the engine at a maximum no load speed of 1950 ± 5 rpm.
5. Be sure that the pilot relief pressure is 3450 kPa (500 psi).
6. Move the travel speed switch to HIGH.
Procedure
1. Slowly move the right control lever for FORWARD travel until the rear pump pressure becomes
27500 kPa (4000 psi). At this point, adjust adjusting screw (22) of ATS valve until the pressure of
speed change port (21) is 0.
2. Fully move the right travel control lever for FORWARD travel until the rear pump pressure
becomes 31400 kPa (4550 psi). Then slowly decrease the pressure to 14000 kPa (2050 psi). At this
point, check to be sure that the pressure of speed change port (21) is 3450 kPa (500 psi).
Pump Flow Tests

NOTE: Before doing the pump flow tests, review the following guidelines:
1. First, check the display of the electronic controller. Reference the module, Electronic Power Unit,
SENR4502. If the electronic controller display checks okay, then perform the operational tests.
2. If operational tests (for example cycle times) indicates that a power problem is common to the
circuits of one pump, then the problem is most likely in the hydraulic system. As a result, Pump
Flow Tests should be made.
NOTE: If the machine does not travel in a straight line at low speed (and travel motors are okay),
then it is recommended that the Negative Control Test be done first to determine if the problem is
located in the pump or in the control valve. Otherwise, first do the Hydraulic Horsepower/High
Pressure Cut Test.
3. If operational tests indicate a power problem common to both pump circuits, then the engine, fuel
or working altitude may be the problem.
Flow Meter Tool Layout
Illustration Of Flow Meter Tool Layout (For Horsepower And HPC Test)
Illustration Of Pump Output Lines (Viewed From Top Of Pumps)

(1) Line (front pump output). (2) Adapter. (3) Manifold (pump output). (4) Line (rear pump output). (5) Tap (front pump
delivery pressure). (6) Tap (rear pump delivery pump).
Hydraulic Horsepower/High Pressure Cut Test (6KF1-589,

7DF1-1404)
Circuit Diagram For Horsepower Control (P-Q)/High Pressure Cut Tests (Front Pump)
(1) Line (front pump output). (4) Line (rear pump output). (5) Pressure tap (front pump circuit). (6) Pressure tap (rear
pump circuit). (7) Negative flow control line (front pump). (8) Control valve. (9) Test hose. (10) Hose port. (11) Cooler.
(12) Test hose. (13) Flow meter. (14) Plug. (15) Pressure port (negative flow signal). (16) Port (power shift). (17)
Pressure port (negative flow signal). (18) Negative flow control line (rear pump). (19) Line (power shift). (20) Test line.
(21) Pressure tap (pilot oil). (22) Pilot oil manifold. (23) Multitach. (24) Main pumps.
This test should be done first because it affects high pressure cut and negative flow control.
Hydraulic Horsepower Test (6KF590-UP, 7DF1405-UP)
Circuit Diagram For Horsepower Control (P-Q)/High Pressure Cut Tests (Front Pump)
This test should be done first because it affects negative flow control.
Hydraulic Horsepower Curve
Horsepower Control Characteristics Adjustment (Front Pump)
Adjustment Screws (Viewed From Left Side)

(25) Front pump horsepower control. (26) Front pump minimum flow. (27) Rear pump horsepower control. (28) Rear
pump minimum flow.
Hydraulic Horsepower Curve
Horsepower Control Characteristics Adjustment (Front Pump)

(25) Front pump horsepower control. (26) Front pump minimum flow. (27) Rear pump horsepower control. (28) Rear
pump minimum flow.
Pumps (Top View)

(1) Line (front pump output). (2) Adapter. (3) Manifold (pump output). (4) Line (rear pump output). (5) Tap (front pump
delivery pressure). (6) Tap (rear pump delivery pressure).
Pumps (Viewed From Right Side)

(15) Pressure port (front pump negative flow signal). (16) Port (power shift). (17) Pressure port (rear pump negative
flow signal).
Pump Compartment
(21) Pressure tap (pilot). (22) Pilot oil manifold.
Preparation
1. Position machine on level ground and stop the engine.
2. Release air pressure in the hydraulic tank by loosening the vent cap on the side of the tank.
3. Install the following:
Radiator Compartment
(10) Hose port.
a. 6000 kPa (870 psi) gauge and tee at pressure tap (21) on the pilot manifold (20).
b. Test line and 60000 kPa (8700 psi) gauge at pressure tap (5) for front pump output.
c. Test line and 60000 kPa (8700 psi) gauge at pressure tap (6) for rear pump output.
d. 6V3121 Multitach Group (23).
e. Disconnect line (7) from the pump. Plug line (7) and leave port (15) open to the air.
f. Disconnect power shift line (19) from the power shift port (16). Plug the line. Install a cap on the
power shift port. Connect test line (20) between tee at tap (21) on the pilot manifold and power shift
port (16) on the right side of the pump.
g. Disconnect pump output line (1). Install plug (14) in the line. Remove plug (10) from the return
line located in the radiator compartment. Install flow meter (13) and test hoses (12) and (9) from the
pump to return line. Make sure the flow meter is fully open before proceeding.
Flow Meter (Typical Illustration)
4. Put mode selector switch in Mode III position and turn AEC switch off.
5. Start the engine and increase the temperature of the hydraulic oil to 45 to 55°C (115 to 130°F) by
stalling an implement circuit using the pilot control lever. Approximately every 30 seconds, operate
the implement to a different position to circulate the oil.
Test
To prevent personal injury or equipment damage from failure of the

flow meter or associated circuit components because of blocked pump
flow, make sure before starting the engine that the flow meter valve is
fully open (turned counterclockwise).
To prevent personal injury and/or equipment damage from failed lines

or components while the flow meter is returned to the open flow
position after a flow test, slowly open the flow meter valve and monitor
pump flow at the same time to make sure flow increases. If pump flow
does not increase as the flow meter is opened, shut the engine off and
determine what is causing the pump not to upstroke.
1. Start the engine. Adjust pilot relief pressure to 2050 kPa (300 psi).
2. Slowly close the flow meter valve and record the temperature, RPM and flow at each of the
following pressures:
Loosen the locknut for horsepower control screw (25). Turn adjustment screw (25) clockwise to
increase flow rate. A quarter turn of the screw changes the flow approximately 20 liter/min. (5.3
U.S. gpm).
NOTE: To adjust horsepower control characteristics for the rear pump, follow the same procedure
as for the front pump.
Maximum Flow Adjustment (Front Pump)
Adjustment Screws (Viewed From Right Side)

(29) Front pump. (30) Rear pump.
Maximum flow should be 185 ± 3 liter/min. (49 ± 1.3 U.S. gpm). If flow is out of specification,
follow the procedure below.
1. Loosen the locknut for screw (29).
2. Turn adjustment screw (29) clockwise to decrease and counterclockwise to increase the flow rate.
A quarter turn of the adjustment screw changes the flow approximately 5 liter/min. (1.3 U.S. gpm).
3. Tighten the locknut for screw (29).
NOTE: To adjust maximum flow for the rear pump, follow the same procedure as for front pump.
Minimum Flow Adjustment (Front Pump)
Minimum flow should be 17.5 ± 2.5 liter/min. (4.6 ± 0.7 U.S. gpm). If flow is out of specification,
follow the procedure below.
1. Loosen the locknut of minimum flow adjustment screw (26).
2. Turn adjustment screw (26) clockwise to increase flow and counterclockwise to decrease flow. A
quarter turn of screw (26) changes the flow approximately 5 liter/min. (1.3 U.S. gpm).
3. Tighten the locknut for screw (26).
NOTE: To adjust minimum flow for the rear pump, adjust screw (28) using the same procedure as
for the front pump.
High Pressure Cut-off Adjustment (Front Pump) (6KF1-589, 7DF1-1404)

(31) Front pump. (32) Rear pump.
NOTE: Hydraulic horsepower (P-Q) adjustment should be done first. This adjustment affects high
pressure cut and minimum flow.
High pressure cut should start at approximately 29400 kPa (4250 psi). Flow should decrease very
fast to a minimum flow of 17.5 liter/min. (4.6 U.S. gpm) at approximately a pressure of 30900 kPa
(4500 psi).
1. To adjust the high pressure cut, turn adjustment screw (31) clockwise to increase pressure and
vise versa to decrease pressure. A quarter turn of the adjusting screw changes the pressure
approximately 4020 kPa (580 psi).
NOTE: To adjust high pressure cut for the rear pump, adjust screw (32) using the same procedure as
for the front pump.
Negative Control Test (Front Pump)
Circuit Diagram For Negative Control Test (Front Pump) (6KF1-589, 7DF1-1404)
The Negative Control Test is a diagnostic test. This test can be used to determine if the problem is in
the pump or in the control valve.
NOTE: The Negative Control Test should not be necessary when the machine travels straight.
Preparation
1. Position the machine on level ground and stop the engine.
2. Release air pressure in hydraulic tank by loosening the vent cap on the side of the hydraulic tank.
3. Install the flow meter between the pump and return line (see the layout for Hydraulic
Horsepower/High Pressure Cut Test).
4. Disconnect negative signal line (7) from pressure port (15). Plug the end of line (7). Connect test
line (20) between tee at tap (21) on the pilot manifold and pressure port (15) on the pump.
Negative Control Test (Front Pump)
Circuit Diagram For Negative Control Test (Front Pump) (6KF590-UP, 7DF1405-UP)
The Negative Control Test is a diagnostic test. This test can be used to determine if the problem is in
the pump or in the control valve.
NOTE: The Negative Control Test should not be necessary when the machine travels straight.
Preparation
1. Position the machine on level ground and stop the engine.
2. Release air pressure in hydraulic tank by loosening the vent cap on the side of the hydraulic tank.
3. Install the flow meter between the pump and return line (see the layout for Hydraulic Horsepower
Test).
4. Disconnect negative signal line (7) from pressure port (15). Plug the end of line (7). Connect test
line (20) between tee at tap (21) on the pilot manifold and pressure port (15) on the pump.
5. Disconnect power shift line (19) from pump power shift port (16). Plug line (19) and leave port
(16) open to the air.
Test
To prevent personal injury or equipment damage from failure of the

flow meter or associated circuit components because of blocked pump
flow, make sure before starting the engine that the flow meter valve is
fully open (turned counterclockwise).
1. Adjust front pump pressure to 6850 kPa (1000 psi) by restricting flow through flow meter (13).
2. Adjust pilot pressure at pilot manifold (22) to the pressure in the chart below. At each pressure,
record the flow from the front pump. The recorded flow must then be corrected by the formula
below the chart.
3. Repeat the above test for the rear pump. This would involve rear pump negative flow control line
(18); negative flow signal pressure port (17); and the rear pump output line (4).
Negative Control Adjustment
A shim is installed in each pump regulator to make negative control adjustment.
However, when measured values are largely different from the above chart, first check a source that
has caused the deviation rather than adjust it by the shim.
Refer to (Hyd #26) machine does not travel straight because of incorrect negative control pressure in
the section "Checking Procedure (Hydraulic System)".
Copyright 1993 - 2020 Caterpillar Inc. Fri Mar 20 14:08:06 EST 2020
Todos los derechos reservados.
Red privada para licenciados del SIS.

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EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGIN...

Hydraulic System Testing And Adjusting

Hydraulic oil pressure can remain in the hydraulic systems on this

3. Inspect all lines and connections for damage or leaks.

4. Inspect control linkage for bent, broken or damaged components.

Checking During Operation

The test conditions for each operational test should be as follows:

1. Set the engine speed at 1950 ± 50 rpm, high idle, no load.

2. Raise hydraulic oil temperature to 45 to 55°C (115 to 130°F)

3. Set the main relief pressure at 31400 kPa (4600 psi).

7. Turn the power mode switch to mode III position.

Travel On Level Ground

4. Bucket must be empty.

3. Measure the travel deviation from the reference straight line.

High speed ... 17.5 ± 1.5 sec.

Low speed ... 28.0 ± 3.0 sec.

Travel Deviation From Straight Line:

High speed ... 1150 ± 350 mm (45.3 ± 13.8 in.)

Low speed ... 1150 ± 350 mm (45.3 ± 13.8 in.)

Travel On Level Ground (Optional Test)

6V3121 Multitach Group.6V4161 Pressure Gauge Kit.

1. Place the machine on level ground.

1. Raise a track for the test as shown in figure.

2. Put a mark on a shoe of the raise track.

High speed ... 22 ± 2 sec./3 turns

Low speed ... 33.5 ± 2.5 sec./3 turns

2. Put the machine in a posture as shown in the figure below.

3. Bucket should be empty.

2. Stop the engine and count three minutes with a stopwatch.

Drift ... 15 ± 5 mm (0.6 ± 0.2 in.)

Swing Speed And Drift (On Level Ground)

3. Bucket should be empty.

Right swing ... 4.7 ± 0.5 sec.

Left swing ... 4.7 ± 0.5 sec.

Right swing ... 1250 ± 150 mm (49 ± 6 in.)

Left swing ... 1250 ± 150 mm (49 ± 6 in.)

Swing Speed And Drift (On Slope)

1. Place the machine on a slope of 12°.

3. The bucket load should be 10300N (2315 lb.).

Test Procedure (Speed)

Test Procedure (Drift) (Swing Brake Released)

2. Put marks on inner and outer races of the swing bearing.

Test Procedure (Drift) (Swing Brake Locked)

2. Put marks on inner and outer races of the swing bearing.

3. Stop the engine.

Swing from 3 o'clock position ... 4.7 ± 0.5 sec.

Swing from 9 o'clock position ... 4.7 ± 0.5 sec.

Swing Drift (Swing Brake Released):

Drift from 3 o'clock position ... 210 ± 70 mm (8.3 ± 2.8 in.)

Drift from 9 o'clock position ... 210 ± 70 mm (8.3 ± 2.8 in.)

Swing Drift (Swing Brake Locked):

Drift from 3 o'clock position ... < = 10 mm (0.4 in.)

Drift from 9 o'clock position ... < = 10 mm (0.4 in.)

Cylinder Rod Drift

1. Place the machine on level ground as shown figure.

2. Fill the bucket with soil.

3. The bucket load should be 10300N (2315 lb.).

4. Stop the engine.